2004 SUBARU FORESTER key

PI-3
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
B: PDI PROCEDURE
Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt
Step Check point
1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle
body for damage and dents. If the protective coating has been removed,
visually check the body paints for small areas of damage or stains.
(2) Visually check the glass and light lenses for any damage and cracks or
excessive gaps to the body sheet metal.
(3) Visually check the plated parts for any damage.
2. Tire check (1) Check the tires for damage, abnormal conditions, and dents on the
wheels.
(2) Check the tire air pressure.
3. Fuse installation If the vehicle is about to be delivered to the customer, attach a room light
fuse.
4. Connection of air conditioner harness If the vehicle is about to be delivered to the customer, connect the air condi-
tioner harness.
5. Check the doors for lock/unlock and open/close
operations.(1) Using the key, check if the door can be locked and unlocked normally.
(2) Open and close all doors to see that there are no abnormal conditions.
6. Operation check of double lock Check that the double lock operates normally.
7. Operation check of the child safety lock system. Check the child safety lock system operates normally.
8. Check the rear gate for lock/unlock and open/
close operations.(1) Check if the rear gate can be unlocked normally from the emergency
door.
(2) Open and close the rear gate to see that there are no abnormal condi-
tions.
(3) Operate the power door locking switch to check that the rear gate is
locked and unlocked normally.
9. Operation check of fuel lid opener lock release
leverOperate the fuel lid opener to check that the fuel lid is unlocked normally.
10. Accessory check Check that the following accessories are provided:
 Owner’s manual
 Warranty booklet
 Service booklet
 Spare key
Jack
Tool set
 Spare tire
11. Operation check of hood lock release system Operate the hood lock release lever to check that the hood opens normally.
12. Battery Check the battery for any abnormal conditions such as rust and trace of bat-
tery fluid leaks.
13. Brake fluid Check the fluid amount.
14. Engine oil Check the oil amount.
15. Transmission fluid (1) Check the fluid amount.
(2) For AT, check the front differential oil.
16. AT front differential oil Check the AT front differential oil amount.
17. Coolant Check the coolant amount.
18. Clutch fluid Check the clutch fluid amount.
19. Window washer fluid Check the window washer fluid amount.
20. Hood latch check Check that the hood is closed and latched securely.
21. Keyless entry system Check that the keyless entry system operates normally.
22. Security system Check that the security system operates normally.
23. Seat (1) Check the seat surfaces for smears or dirt.
(2) Check the seat installation conditions and functionality.
24. Seat belt Check the seat belt installation conditions and functionality.
25. Wheel alignment Check that the wheel alignments are properly adjusted.

PI-5
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
1. APPEARANCE CHECK
1) If the vehicle is covered with protective coating,
visually check the vehicle body for damage and
dents.
2) If there is no protective coating, check the body
paints for small areas of damage or stains and re-
pair as necessary.
3) Check the window glass, door glass, and lights
for any cracks or damage and repair or replace the
parts as necessary.
4) Check the plated parts, such as the grilles and
door knobs, for damage or loss of gloss and repair
or replace the parts as necessary.
2. TIRE CHECK
 Check the tire outer faces for any damage.
 Check the tire air pressure by referring to the fol-
lowing table.
3. FUSE INSTALLATION
A vehicle just delivered has no fuse for the room
lamp circuit to prevent battery discharge. Attach a
15 A fuse (A) as shown in the figure.
4. CONNECTION OF AIR CONDITIONER
HARNESS
A vehicle just delivered has its air conditioner har-
ness disconnected to protect the air conditioner
compressor. Connect the harness as shown in the
figure.
5. CHECK THE DOORS FOR LOCK/UN-
LOCK AND OPEN/CLOSE OPERATIONS.
1) Using the key, lock and unlock the door several
times to check for normal operation. Open and
close the door several times for smooth movement.Tire sizeTire inflation pressure
kPa (kg/cm2, psi)
Front Rear
205/70R15
200 (2.0, 29) 190 (1.9, 28) 215/60R16
P215/60R16
PI-00001(A)
(A) Unlock
(B) Lock
PI-00002
PI-00070
(A)
(B)

PI-6
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
2) Close the driver’s door completely, and place the
door lock knob (A) to the lock position. Then pull in-
side door handles (B) to ensure that doors will not
open.
For other doors, place the door lock knob (A) to the
lock positions and then pull the inside door handles
to ensure that the doors will not open.
3) Press the driver’s side power door lock switch to
lock side. Check that all doors including rear gate
are locked.
4) Press the driver’s side power door lock switch to
unlock side. Check that all doors including rear
gate are unlocked.6. CHECK DOUBLE LOCK OPERATION.
1) Fully open all the windows.
2) Remove the key.
3) Lock all the doors using the key or keyless trans-
mitter.
4) Verify that all the doors including rear gate are
not unlocked when pressing power door lock switch
to unlock side.
5) Verify that the door is not opened when operat-
ing door lock knob to unlock position and pulling in-
ner remote. Perform the same check for other
doors.
6) When the ignition key is turned to ON position in
double lock condition, confirm all doors are re-
leased from double lock and then all doors and rear
gate is unlocked.
7. CHECK THE OPERATION OF CHILD
SAFETY LOCKS
1) Set the child safety lock on both rear doors to the
lock positions.
2) Close the rear doors completely.
3) Check that the lock levers of the rear doors are in
the unlock positions. Then, pull the inside door han-
dles of the rear doors to ensure that the doors will
not open.
4) Next, pull the outside door handles of the rear
doors to ensure that the doors will open.
(A) Door lock knob
(B) Inside door handle
PI-00004
(A)
(B)
PI-00074
PI-00107
(A) Unlock
(B) Lock
(C) Child safety lock
PI-00084
(A)
(B)
(C)

PI-7
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
8. CHECK THE REAR GATE FOR LOCK/
UNLOCK AND OPEN/CLOSE OPERA-
TIONS.
1) Open and close the rear gate several times for
smooth movement.
2) Operate the rear gate lever to check that the rear
gate is locked and unlocked normally.
(1) Remove the blind cover inside the rear gate.
(2) Using a screwdriver, check the rear gate is
lock/unlock.
9. OPERATION CHECK OF FUEL LID
OPENER LOCK RELEASE LEVER
Operate the fuel lid opener and verify that the fuel
lid opens normally. Check that the filler cap is se-
curely closed.
10.ACCESSORY CHECK
Check that the following accessories are provided
in the luggage compartment or cargo area.
 Owner’s manual
 Warranty booklet
 Service booklet
 Spare key
Jack
Tool set
 Spare tire
PI-00006
PI-00007
(A) Jack
(A) Jack handle
PI-00008
(A)
PI-00009(A)

PI-10
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
21.KEYLESS ENTRY SYSTEM
Check the keyless entry system operations as fol-
lows:
 Fully open all the door windows.
 Remove the key from the ignition switch and
close all the doors including rear gate.
 Press the “LOCK” button on the keyless transmit-
ter once and check if all the doors are locked, and
the hazard light flashes once.
 Press the “UNLOCK” button on the keyless
transmitter once and check if the all doors are un-
locked, and the hazard light flashes twice. Close all doors and rear gate, press the “LOCK”
button of the keyless transmitter. Press the “UN-
LOCK” button of the keyless transmitter and wait
for 30 seconds. Check that all doors and the rear
gate are automatically locked again.
22.SEAT
Check that each seat provides full functionality in
sliding and reclining. Check all available functions
of the rear seat.
23.SEAT BELT
Pull out the seat belt and then release it. Check that
the belt webbing retracts smoothly.
24.WHEEL ALIGNMENT
Check the wheel alignments. Alignment.>
25.TEST MODE CONNECTORS
Turn the ignition switch to ON and check that the
malfunction indicator light starts blinking. If the light
blinks, return the ignition key to LOCK and discon-
nect the test mode connector. Then, turn the igni-
tion key to ON again. If the malfunction indicator
light blinks at that time in spite of the disconnected
test mode connector, carry out an engine diagno-
sis.
26.STARTING CONDITION
Start the engine and check that the engine starts
smoothly. If any battery voltage problems are
found, recharge or replace the battery. If any nois-
es are observed, immediately stop the engine and
check and repair the necessary components.
27.EXHAUST SYSTEM
Listen to the exhaust noise to see if no unusual
noises are heard.
28.INDICATOR LIGHT
Check that all the indicator lights are off.
PI-00108
PI-00109
PI-00110
PI-00111
(A) Test mode connector (Green)
PI-00076
(A)

PI-11
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
29.CLOCK
Check the clock for normal operations and enough
accuracy.
30.RADIO
Check the radio for full functionality and normal
noise level. Also check the CD unit operations.
31.FRONT ACCESSORY POWER SUPPLY
SOCKET
Check the front accessory power supply socket op-
erations.
32.LIGHTING SYSTEM
 Check the headlight operations.
 Check the brake light operations.
 Check the other lights for normal operations.
33.WINDOW WASHER
Check that the window washer system injects
washer fluid to the specified area of windshield
shown in the figure.
Front injection position:
A: 350 mm (13.78 in)
B: 150 mm (5.91 in)
C: 275 mm (10.83 in)
D: 600 mm (23.62 in)Rear injection position:
A: 35 mm (1.38 in)
B: 72
°
34.WIPER
Check the front and rear wipers for normal opera-
tions.
35.POWER WINDOW OPERATION CHECK
Manipulate the power window switches one by one
to check that each of the power windows goes up
and down with no noises.
36.BRAKE TEST
Check the foot brake for normal operations.
37.PARKING BRAKE
Check the parking brake for normal operations.
38.AT SHIFT CONTROL
1) Turn the ignition switch to ON.
2) Check that the select lever can not be moved
from “P” range when brake pedal is not depressed.
3) Check that the select lever can be moved from
“P” range when brake pedal is depressed.
4) Select the select lever to except “P” range.
5) Check that the ignition key can not be removed
from ignition switch when ignition switch is turned
to OFF.
WW-00107
(A) (A)
(B) (B)
(C)
(D)
(1) Nozzle
PI-00081
(1)
A
B

ME(H4SO)-9
MECHANICAL
General Description
4. CYLINDER HEAD AND VALVE ASSEMBLY
(1) Exhaust valve (4) Valve spring seat (7) Retainer
(2) Intake valve (5) Intake valve oil seal (8) Retainer key
(3) Valve guide (6) Valve spring (9) Exhaust valve oil seal
ME-00188
(2)
(2)(6)
(6)(3)
(3)(4)
(4)(5)
(9)(7)
(8)
(7)
(8)
(1)(1)

ME(H4SO)-13
MECHANICAL
General Description
(1) Flywheel (MT model) (9) Snap ring (17) Crankshaft bearing #2, #4
(2) Reinforcement (AT model) (10) Connecting rod bolt (18) Crankshaft bearing #5
(3) Drive plate (AT model) (11) Connecting rod
(4) Top ring (12) Connecting rod bearingTightening torque: N
⋅m (kgf-m, ft-lb)
(5) Second ring (13) Connecting rod capT1: 45 (4.6, 33.3)
(6) Oil ring (14) CrankshaftT2: 72 (7.3, 52.8)
(7) Piston (15) Woodruff key
(8) Piston pin (16) Crankshaft bearing #1, #3