2004 SUBARU FORESTER Engine mount

EN(H4DOTC 2.5)-54
ENGINE (DIAGNOSTIC)
Diagnostics for Engine Starting Failure
16.Diagnostics for Engine Starting Failure
A: PROCEDURE
1. Check for fuel amount.
↓
2. Inspection of starter motor circuit. Failure.>
↓
3. Inspection of ECM power supply and ground line. LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.>
↓
4. Inspection of ignition control system. Starting Failure.>
↓
5. Inspection of fuel pump circuit.
↓
6. Inspection of fuel injector circuit. Failure.>

CS-8
CONTROL SYSTEM
Select Lever
2. Select Lever
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Shift the select lever to “N” range.
4) Lift-up the vehicle.
5) Remove the rear exhaust pipe and muffler.
 Non-turbo model
Pipe.> fler.>
 Turbo model
haust Pipe.> AL, Muffler.>
6) Remove the heat shield cover. (If equipped)
7) Disconnect the cable from select lever, and then
remove the cable bracket.
8) Lower the vehicle.
9) Remove the console box. MOVAL, Console Box.>
10) Disconnect the connectors, then remove the
four bolts to take out the select lever assembly from
body.
B: INSTALLATION
1) Mount the select lever onto vehicle body.
2) Tighten the four bolts to install the select lever to
vehicle body, then connect the connector.
Tightening torque:
13 N·m (1.3 kgf-m, 9.4 ft-lb)
3) Install the console box. LATION, Console Box.>
4) Shift the select lever to “N” range.
5) Lift-up the vehicle.
6) Shift the range select lever to “N” range.
7) Insert the thread portion of inner cable into con-
nector hole of the select lever, and fix the outer ca-
ble end to bracket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
8) Adjust the select cable position. ADJUSTMENT, Select Cable.>
9) After completion of fitting, make sure the select
lever operates smoothly all across the operating
range.
10) Install the heat shield cover. (If equipped)
11) Install the rear exhaust pipe and muffler.
 Non-turbo model
haust Pipe.> TION, Muffler.>
 Turbo model
Exhaust Pipe.> STALLATION, Muffler.>
12) Inspect the following items. If the following in-
spection reveals problems, adjust the select cable
and inhibitor switch. MENT, Select Cable.> MENT, Inhibitor Switch.>
(1) The engine starts operating when select le-
ver is in “P” range, but not in other ranges.
(2) The back-up light is lit when the select lever
is in “R” range, but not in other ranges.
(3) Select lever and indicator ranges are matched.
(A) Adjusting nut
(B) Cable bracket
CS-00017(B)(A)
CS-00018
CS-00168

4AT-30
AUTOMATIC TRANSMISSION
Automatic Transmission Fluid
2. Automatic Transmission Flu-
id
A: INSPECTION
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the ATF temperature when checking
ATF level.
1) Raise the ATF temperature by driving a distance
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en-
gine to raise ATF temperature to 70 — 80°C (158
— 176°F) on Subaru Select Monitor. 4AT(H4SO)-18, READ CURRENT DATA, OPERA-
TION, Subaru Select Monitor.>
2) Make sure the vehicle is level.
3) After selecting all positions (P, R, N, D, 3, 2, 1),
set the select lever in “P” range. Measure the ATF
level with engine idling for one or two minutes.
4) Make sure that ATF level is above the center of
upper level and lower level at HOT side.
If the ATF level is below the lower level, check for
leaks in the transmission. If there are leaks, it is
necessary to repair or replace gasket, oil seals,
plugs or other parts.
5) If the ATF level is below the center between up-
per level and lower level, add the recommended
ATF until the fluid level is found above the center
between upper level and lower level marks.
CAUTION:
 Use care not to exceed the upper level.
 Remember that the addition of ATF to the up-
per limit mark when the transmission is cold
will overfilling of ATF, causing a transmission
failure.
6) Check ATF level after raising ATF temperature
to 70 — 80°C (158 — 176°F) by running the vehicle
or by idling the engine again.
B: REPLACEMENT
1) Lift-up the vehicle.2) Drain the ATF completely.
CAUTION:
Directly after the engine has been running, the
ATF is hot. Be careful not to burn yourself.
3) Replace the gasket with new one, and then tight-
en the drain plug (ATF).
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
4) Lower the vehicle.
5) Pour ATF from the ATF charge pipe.
Recommended fluid:
DEXRON III type automatic transmission flu-
id
Capacity:
Fill the same amount of ATF drained from
drain plug hole.
CAPACITY WHEN TRANSMISSION IS OVER-
HAULED:
2.0 L NON-TURBO MODEL
8.4 — 8.72 (8.9 — 9.2 US qt, 7.4 — 7.7 Imp
qt)
EXCEPT 2.0 L NON-TURBO MODEL
9.3 — 9.62 (9.8 — 10.1 US qt, 8.2 — 8.4 Imp
qt)
6) Check the level and leaks of ATF.
mission Fluid.>
(A) ATF level gauge
(B) Upper level
(C) Lower level
AT-00674
COLD
LFHOT LF
(C)
(C)
(B)
(B)
(A)(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)

4AT-32
AUTOMATIC TRANSMISSION
Road Test
4. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diag-
nose the condition of the automatic transmission.
NOTE:
When performing the test, do not exceed posted
speed limit.
2. D RANGE SHIFT FUNCTION
Check shifting between 1st ←→ 2nd ←→ 3rd ←→
4th while driving on normal city streets.
3. D RANGE SHIFT SHOCK
Check the shock level when shifting up during nor-
mal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Also check the
kick-down shock level.
5. ENGINE BRAKE OPERATION
 Check the 3rd gear engine brake when shifting
down from D ←→ 3rd range while driving in 4th
gear of D range [50 — 60 km/h (31 — 37 MPH)].
 Check the 2nd gear engine brake when shifting
between 3rd ←→ 2nd range while driving in the 3rd
range of 3rd gear [40 — 50 km/h (25 — 31 MPH)].
 Check the 1st gear engine brake when shifting
between 2nd ←→ 1st range while driving in the 2nd
range of 2nd gear [20 — 30 km/h (12 — 19 MPH)].
6. LOCK-UP FUNCTION
 Check that rpm does not change sharply when
the axle pedal is lightly depressed when driving on
flat roads at 60 km/h (37 MPH).
 Check slip lock-up with following procedure.
Subaru Select Monitor is needed for checking (EC,
EK model).
Before start checking, check that the DTC is not ex-
isted using Subaru Select Monitor. When the DTC
is existed, perform the collective action with DTC
and check that the DTC is not existed again, and
then start the checking.
1) The check performed on flat and straight road or
free roller.
NOTE:
 Slip lock-up does not operate when the vehicle is
lifted up, because of not occurring surface resis-
tance.
 Also checking on the free roller, check with de-
pressing foot brake lightly to make the checking
easier, because the surface resistance will be defi-
cient2) Connect the Subaru Select Monitor.
3) Check ATF temperature using Subaru Select
Monitor.
NOTE:
 ATF temperature is between 50 — 100°C (122
— 212°F).
 When the temperature is low, warm-up the ATF
by running the vehicle or etc.
4) Start the engine, and make the lock-up duty be
able to read on data display of Subaru Select Mon-
itor.
5) 35 — 40 Drive the vehicle at a constant speed of
35 — 40 km/h (22 — 25 MPH).
6) Read the lock-up duty while vehicle is running.
Standard value:
25 — 45%
NOTE:
On the free roller, the value sometimes lowers.
 Slip lock-up control is not operating when the
lock-up duty is less than 5%, or when the lock-up
duty goes down immediately after starts rise. On
these cases, improper ATF or deterioration of ATF
may be the cause. Check the amount of ATF or re-
place them, and then recheck it.
7. P RANGE OPERATION
Stop the vehicle on an uphill grade of 5% or more
and shift to “P” range. Check that the vehicle does
not move when the parking brake is released.
8. NOISE AND VIBRATION
Check for unusual sounds and vibration while driv-
ing and during shifting.
9. CLIMBING CONTROL FUNCTION
 Check that the gear remains in 3rd when going
up a grade.
 Check that the gear remains in 3rd when apply-
ing the brakes while going down a grade.
10.TRANSFER CLUTCH
Check tight corner braking when the vehicle started
with steering fully turned.
11.OIL LEAKS
After the driving test, inspect for oil leaks.

5MT-111
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic
26.General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION
Symptom Possible cause Remedy
1. Gears are difficult to intermesh.
N
OTE:
The cause for difficulty in shifting gears
can be classified into two kinds: one is
malfunction of the gear shift system and
the other is malfunction of the transmis-
sion. However, if the operation is heavy
and engagement of the gears is difficult,
defective clutch disengagement may also
be responsible. Check whether the clutch
is correctly functioning, before checking
the gear shift system and transmission.(a) Worn, damaged or burred chamfer of
internal spline of sleeve and reverse
driven gearReplace.
(b) Worn, damaged or burred chamfer of
spline of gearsReplace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchro-
nizer ring and gear cone or wear Correct or replace.
2. Gear slips out.
 Gear slips out when coasting on rough
road.
 Gear slips out during acceleration.(a) Defective pitching stopper adjustment Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork
rail springReplace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines
of synchronizer hub and synchronizer
sleeveReplace.
(f) Worn tooth step of synchronizer hub Replace.
(g) Worn 1st driven gear and driven shaft Replace.
(h) Worn 2nd driven gear and 2nd bush Replace.
(i) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmis-
sion.
N
OTE:
If an unusual noise is heard when the ve-
hicle is parked with its engine idling and if
the noise ceases when the clutch is disen-
gaged, it may be considered that the
noise comes from the transmission.(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bearings
NOTE:
If the trouble is only wear of the tooth sur-
faces, merely a high roaring noise will oc-
cur at high speeds, but if any part is
broken, rhythmical knocking sound will be
heard even at low speeds.Replace.

CL-42
CLUTCH SYSTEM
General Diagnostic Table
12.General Diagnostic Table
A: INSPECTION
1. CLUTCH
Symptom Possible cause Corrective
1. Clutch slippage.
It is hard to perceive clutch slippage in
the early stage, but pay attention to the
following symptoms
 Engine speed up when shifting.
 High speed driving is impossible; espe-
cially rapid acceleration impossible and
vehicle speed does not increase in pro-
portion to an increase in engine speed.
 Power falls, particularly when ascend-
ing a slope, and there is a smell of burn-
ing of the clutch facing.
 Method of testing: Put the vehicle in
stationary condition with parking brake
fully applied. Disengage the clutch and
shift the transmission gear into the first.
Gradually allow the clutch to engage
while gradually increasing the engine
speed. The clutch function is satisfactory
if the engine stalls. However, the clutch is
slipping if the vehicle does not start off
and the engine does not stall.(a) Clutch facing smeared by oil Replace.
(b) Worn clutch facing Replace.
(c) Deteriorated diaphragm spring Replace.
(d) Distorted pressure plate or flywheel Replace.
(e) Defective release bearing holder Replace.
2. Clutch drags.
As a symptom of this trouble, a harsh
scratching noise develops and control
becomes quite difficult when shifting
gears. The symptom becomes more
apparent when shifting into the first gear.
However, because much trouble of this
sort is due to defective synchronization
mechanism, carry out the test as
described after.
 Method of testing: DIAGNOSTIC DIAGRAM OF CLUTCH
DRAG, INSPECTION, General Diagnos-
tic Table.>
It may be judged as insufficient disen-
gagement of clutch if any noise occurs
during this test.(a) Worn or rusty clutch disc hub spline Replace the clutch disc.
(b) Excessive deflection of clutch disc
facingReplace.
(c) Malfunction of crankshaft pilot bearing Replace.
(d) Cracked clutch disc facing Replace.
(e) Stuck clutch disc (smeared by oil or
water)Replace.
3. Clutch chatters.
Clutch chattering is an unpleasant vibra-
tion to the whole body when the vehicle is
just started with clutch partially engaged.(a) Adhesion of oil on the facing Replace the clutch disc.
(b) Weak or broken torsion spring Replace the clutch disc.
(c) Defective facing contact or excessive
disc wornReplace the clutch disc defection.
(d) Warped pressure plate or flywheel Replace.
(e) Loose disc rivets Replace the clutch disc.
(f) Loose engine mounting Retighten or replace the mounting.
(g) Improper adjustment of pitching stop-
perAdjustment.

CL-43
CLUTCH SYSTEM
General Diagnostic Table
2. CLUTCH PEDAL
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
4. Noisy clutch
Examine whether the noise is generated
when the clutch is disengaged, engaged,
or partially engaged.(a) Broken, worn or unlubricated release
bearingReplace the release bearing.
(b) Insufficient lubrication of pilot bearing Replace.
(c) Loose clutch disc hub Replace the clutch disc.
(d) Loose torsion spring retainer Replace the clutch disc.
(e) Deteriorated or broken torsion spring Replace the clutch disc.
5. Clutch grabs.
When starting the vehicle with the clutch
partially engaged, the clutch engages
suddenly and the vehicle jumps instead
of making a smooth start.(a) Grease or oil on facing Replace the clutch disc.
(b) Deteriorated cushioning spring Replace the clutch disc.
(c) Worn or rusted spline of clutch disc or
main shaftTake off rust, apply grease or replace the
clutch disc or main shaft.
(d) Deteriorated or broken torsion spring Replace the clutch disc.
(e) Loose engine mounting Retighten or replace the mounting.
(f) Deteriorated diaphragm spring Replace.
Trouble Corrective action
Insufficient pedal play Adjust pedal play.
Clutch pedal free play insufficient Adjust pedal free play.
Excessively worn and damaged pedal shaft and/or bushing Replace the bushing and/or shaft with a new one.
Step Check Yes No
1 CHECK GEAR NOISE.
1) Start the engine.
2) Disengage the clutch and shift quickly from
neutral to reverse in idling condition.Is there any abnormal noise
from the transmission gear?Go to step 2.Clutch is normal.
2 CHECK GEAR NOISE.
Disengage the clutch at idle and shift from neu-
tral to reverse within 0.5 — 1.0 seconds.Is there any abnormal noise
from the transmission gear?Go to step 3.Defective trans-
mission or exces-
sive clutch drag
torque. Inspect the
pilot bearing,
clutch disc, trans-
mission and clutch
disc hub spline.
3 CHECK GEAR NOISE.
1) Disengage the clutch at idle and shift from
neutral to reverse within 0.5 — 1.0 seconds.
2) With the clutch disengaged, shift from N to
R, R to N several times.Is there any abnormal noise
from the transmission gear?Defect in clutch
disengaging.
Inspect the clutch
disc, clutch cover,
clutch release, and
clutch pedal free
play.Clutch and fly-
wheel seizure.
Inspect the clutch
disc, spline of
clutch disc hub. Symptom Possible cause Corrective