2004 SUBARU FORESTER mirror

FUJI HEAVY INDUSTRIES LTD. G8080GE7
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTIC) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEM WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOW/MIRROR GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB

SPC-5
SPECIFICATION
Forester
J: WEIGHT
1. LHD MODEL
★: For the option codes, refer to ID section. Option code
★EC K4 KS
Model 2.0 L Non-turbo 2.5 L Non-turbo
Grade 2.0 X 2.5 X
Transmission 5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.)Front kgf (lb)760
(1,675)775
(1,710)775
(1,710)790
(1,740)780
(1,720)800
(1,765)
Rear kgf (lb)600
(1,325)600
(1,325)595
(1,310)595
(1,310)620
(1,365)620
(1,365)
Total kgf (lb)1,360
(3,000)1,375
(3,035)1,370
(3,020)1,385
(3,050)1,400
(3,085)1,420
(3,130)
Maximum permissi-
ble axle weight
(M.P.A.W.)Front kgf (lb)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)
Rear kgf (lb)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)
Maximum permissi-
ble weight (M.P.W.)Total kgf (lb)1,880
(4,140)1,880
(4,140)1,880
(4,140)1,880
(4,140)1,880
(4,140)1,880
(4,140)
OptionSport package base — — — — — —
Aluminum wheel❍❍❍❍❍❍
Front fog light — — — —❍❍
Cruise control — — — —❍❍
High-grade audio — — — — — —
Sport steering — — — — — —
Leather package base — — — — — —
Leather seat, Leather
door trim——————
Navigation system ——————
Air conditioner — —❍❍❍❍
Side airbag — — — — — —
Sunroof — — — — — —
Self-leveling function Rr❍❍————
Cold area pack A — — — — — —
Cold area pack B — — — — — —
Cold area pack C — — — — — —
Cold area pack D❍❍————
Heated mirrors❍❍————
Security system — — — — — —

SPC-6
SPECIFICATION
Forester
★: For the option codes, refer to ID section. Option code
★EC K4
Model2.0 L Turbo
Grade2.0 XT
Transmission 5MT 4AT 5MT 4AT
Curb weight (C.W.)Front kgf (lb) 810 (1,785) 830 (1,830) 815 (1,795) 835 (1,840)
Rear kgf (lb) 620 (1,365) 620 (1,365) 630 (1,390) 630 (1,390)
Total kgf (lb) 1,430 (3,150) 1,450 (3,195) 1,445 (3,185) 1,465 (3,230)
Maximum permissible axle
weight (M.P.A.W.)Front kgf (lb) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225)
Rear kgf (lb) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280)
Maximum permissible
weight (M.P.W.)Total kgf (lb)1,950 (4,295) 1,950 (4,295) 1,950 (4,295) 1,950 (4,295)
OptionSport package base — — — —
Aluminum wheel — — — —
Front fog light❍❍❍❍
Cruise control❍❍—❍
High-grade audio — — — —
Sport steering — — — —
Leather package base❍❍❍❍
Leather seat, Leather door trim — — —❍
Navigation system — — — —
Air conditioner❍❍❍❍
Side airbag❍❍❍❍
Sunroof — —❍❍
Self-leveling function Rr❍❍——
Cold area pack A — — — —
Cold area pack B❍❍——
Cold area pack C — — — —
Cold area pack D — — — —
Heated mirrors❍❍——
Security system ————

SPC-7
SPECIFICATION
Forester
2. RHD MODEL
★: For the option codes, refer to ID section. Option code
★EK EK
Model 2.0 L Non-turbo 2.0 L Turbo
Grade 2.0 X 2.0 XT
Transmission 5MT 4AT 5MT 4AT
Curb weight (C.W.)Front kgf (lb) 775 (1,710) 790 (1,740) 815 (1,795) 835 (1,840)
Rear kgf (lb) 600 (1,325) 600 (1,325) 635 (1,400) 635 (1,400)
Total kgf (lb) 1,375 (3,035) 1,390 (3,065) 1,450 (3,195) 1,470 (3,240)
Maximum permissible axle
weight (M.P.A.W.)Front kgf (lb) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225)
Rear kgf (lb) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280)
Maximum permissible
weight (M.P.W.)Total kgf (lb)1,880 (4,145) 1,880 (4,145) 1,950 (4,300) 1,950 (4,300)
OptionSport package base ————
Aluminum wheel❍❍——
Front fog light — —❍❍
Cruise control — —❍❍
High-grade audio ————
Sport steering ————
Leather package base — —❍❍
Leather seat, Leather door trim — —❍❍
Navigation system ————
Air conditioner❍❍❍❍
Side airbag — —❍❍
Sunroof — —❍❍
Self-leveling function Rr❍❍❍❍
Cold area pack A❍❍——
Cold area pack B ————
Cold area pack C — —❍❍
Cold area pack D ————
Heated mirrors❍❍❍❍
Security system — —❍❍

SPC-8
SPECIFICATION
Forester
★: For the option codes, refer to ID section. Option code
★KA
Model 2.5 L Non-turbo 2.5 L Turbo
Grade 2.5 X 2.5 XS 2.5 XT
Transmission 5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.)Front kgf (lb)765
(1,685)785
(1,730)760
(1,675)780
(1,720)815
(1,795)835
(1,840)
Rear kgf (lb)610
(1,345)610
(1,345)605
(1,335)605
(1,335)610
(1,345)610
(1,345)
Total kgf (lb)1,375
(3,030)1,395
(3,075)1,365
(3,010)1,385
(3,055)1,425
(3,140)1,445
(3,185)
Maximum permissi-
ble axle weight
(G.A.L.R.)Front kgf (lb)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)
Rear kgf (lb)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)
Maximum permissi-
ble weight (G.V.M.)Total kgf (lb)1,950
(4,300)1,950
(4,300)1,950
(4,300)1,950
(4,300)1,950
(4,300)1,950
(4,300)
OptionSport package base — — — — — —
Aluminum wheel — — — — — —
Front fog light — —❍❍❍❍
Cruise control❍❍❍❍❍❍
High-grade audio — — — — — —
Sport steering — — — —❍❍
Leather package base — — — —❍❍
Leather seat, Leather
door trim——————
Navigation system ——————
Air conditioner❍❍❍❍❍❍
Side airbag — — — — — —
Sunroof — — — — — —
Self-leveling function Rr — —❍❍❍❍
Cold area pack A — — — — — —
Cold area pack B — — — — — —
Cold area pack C — — — — — —
Cold area pack D — — — — — —
Heated mirrors — — — — — —
Security system — — — — — —

SPC-9
SPECIFICATION
Forester
3. OPTION
Option Front kgf (lb) Rear kgf (lb) Total kgf (lb)
Sport package base 0.1 (0.2) 0.4 (0.9) 0.5 (1.1)
Aluminum wheel15 IN−6.5 (−14.3)−6.5 (−14.3)−13.0 (−28.6)
16 IN−7.3 (−16.1)−7.3 (−16.1)−14.6 (−32.2)
Front fog light 0.7 (1.5)−0.1 (−0.2) 0.6 (1.3)
Cruise control 1.5 (3.3) 0.2 (0.5) 1.7 (3.8)
High-grade audio 0.8 (1.8) 0.4 (0.9) 1.2 (2.7)
Sport steering 0.2 (0.5) 0.1 (0.2) 0.3 (0.7)
Leather package base 0.0 (0.0) 0.0 (0.0) 0.0 (0.0)
Leather seat, Leather door trim 1.2 (2.6) 3.0 (6.6) 4.2 (9.2)
Navigation system−1.7 (−3.7)−0.8 (−1.8)−2.5 (−5.5)
Air conditioner 16.9 (37.3)−1.4 (−3.1) 15.5 (34.2)
Side airbag 2.0 (4.4) 2.4 (5.3) 4.4 (9.7)
Sunroof 3.5 (7.7) 13.2 (29.1) 16.7 (36.8)
Self-leveling function RrNon-turbo 0.1 (0.2) 3.0 (6.6) 3.1 (6.8)
Turbo 0.1 (0.2) 3.1 (6.8) 3.2 (7.0)
Cold area pack A 0.1 (0.2) 0.2 (0.5) 0.3 (0.7)
Cold area pack B 0.1 (0.2) 0.3 (0.7) 0.4 (0.9)
Cold area pack C 0.1 (0.2) 0.3 (0.7) 0.4 (0.9)
Cold area pack D 0.0 (0.0) 0.0 (0.0) 0.0 (0.0)
Heated mirrors 0.0 (0.0) 0.0 (0.0) 0.0 (0.0)
Security system 0.3 (0.7) 0.3 (0.7) 0.6 (1.4)

RM-6
RECOMMENDED MATERIAL
Recommended Materials
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Grease MT main shaft FX 2200 clutch grease 000040901 —
Clutch master cylinder
push rodSlicolube G-40M 004404003 —
 Gear shift lever
 Select lever
 Clutch operating cyl-
inder
 Accelerator pedal
 Clutch pedal
 Brake pedal
 Hill holder
 Clutch bearing
 Clutch release lever
 Steering shaft bear-
ingSUNLIGHT2 003602010 —
Steering gearbox Valiant grease M-2 003608001 —
Disc brake Niglube RX-2 K0779GA102 —
 Drum brake
 Drum brake wheel
cylinderMolykote No. 7439 003602001 —
 Brake pad
Brake shoeMolykote AS-880N K0777YA010 —
Front axle AARi One luber C — —
Front axle AC HTBJ — —
Rear axle BJ Molylex No. 2 003601001 —
Rear axle EBJ NTG2218 — —
Rear axle DOJ VU-3A702 23223GA050 —
 Water pump
Door latch
Door strikerSlicolube G-30M 004404002 —
Adhesive Application point Recommended Item number Alternative
Adhesive Windshield and body Dow Automotive’s
Adhesive: Gurit-ESSEX
Betaseal 1502 or equivalent
Glass primer: Betawipe VP
04604 or Betawipe 5001
Paint surface primer: Betap-
rime 5402——
Soft vinyl Cemedine 540 — 3M’s EC-776 EC-847 or EC-1022
(Spray type)
Momentary sealant Cemedine 3000 — Armstrong’s Eastman 910
Inner rearview mirror
baseREPAIR KIT IN MR 65029FC000 — Grease Application point Recommended Item number Alternative

PM-30
PERIODIC MAINTENANCE SERVICE
Brake Line
18.Brake Line
A: INSPECTION
1. BRAKE LINE
1) Check scratches, swelling, corrosion, traces of
fluid leakage on the brake hoses or pipe joints.
2) Check the possibility of adjacent parts interfering
with brake pipes or hoses during driving, and loose
connections or clamps.
3) Check any trace of fluid leakage, scratches, etc.
on the master cylinder, wheel cylinder and pres-
sure control valve.
NOTE:
 When the brake fluid level in the reservoir tank is
lower than the specified limit, the brake fluid warn-
ing light on the combination meter will come on.
 Visually check the brake hose (using a mirror
where it is difficult to see) for any damage.
B: CHECKING
1. SERVICE BRAKE
1) Check the free play of brake pedal with a force of
less than 10 N (1 kgf, 2 lb).
Brake pedal free play:
0.5 — 2.0 mm (0.02 — 0.08 in)
2) If the free play is out of specifications above, ad-
just the brake pedal as follows.
(1) Be sure the engine is off. (No vacuum is ap-
plied to brake booster.)
(2) There should be play between brake boost-
er clevis and pin at brake pedal installing por-
tion.
[Depress brake pedal pad with a force of less
than 10 N (1 kgf, 2 lb) to a stroke of 0.5 to 2.0
mm (0.02 to 0.08 in).]
(3) Depress the surface of brake pad by hand.
(1) Front brake hose
(2) Front brake pipe
(1) Brake pipe
(2) Rear brake hose
(3) Clamp
BR-00095
(1)
(2)
(1)
(3)
(3) (2)
BR-00096
(A) Brake pedal free play
PM-00078
(A)