2003-2004 Subaru Forester Service & Repair Manual

2003-2004 PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G8080GE1) ENGINE SECTION 1 (Pub.No.G8080GE2) ENGINE SECTION 2 (Pub.No.G8080GE3) ENGINE SECTION 3 (Pub.No.G8080GE4) TRANSMISSION SECTION (Pub.No.G8080GE5) CHASSIS SECTION (Pub.No.G8080GE6) BODY SECTION (Pub.No.G8080GE7) WIRING SYSTEM SECTION (Pub.No.G8080GE8)

FUJI HEAVY INDUSTRIES LTD. G8080GE1 03-04 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION 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 specifications contained in this manual are based on the latest product information available at the time of publication approval. FOREWORD FW HOW TO USE THIS MANUAL HU SPECIFICATION SPC PRECAUTION PC NOTE NT IDENTIFICATION ID RECOMMENDED MATERIAL RM PRE-DELIVERY INSPECTION PI PERIODIC MAINTENANCE SERVICE PM

FOREWORD FW Page 1. Foreword ..................................................................................................... 2

FW-2 FOREWORD Foreword 1. Foreword A: FOREWORD These manuals are used when performing maintenance, repair, or diagnosis of the Subaru FOREST- ER. Applied model: SG***** from 2004MY The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc. may be made without notice.

HOW TO USE THIS MANUAL HU Page 1. How to Use This Manual ............................................................................. 2

HU-2 HOW TO USE THIS MANUAL How to Use This Manual 1. How to Use This Manual A: HOW TO USE THIS MANUAL 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specification, maintenance and other information for the components are included, and diagnosis information has also been added where necessary. 2. INDEX The first page has an index with tabs.

HU-3 HOW TO USE THIS MANUAL How to Use This Manual 3. COMPONENTS Illustrations are listed for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the parts, refer to parts catalogue. Example: HU-00001 (14) (9) (8) (7) (6) (10) (4) (10) (22) (11) (19) (17) (15) (13) (12) (18) (16) (1) (2) (3) (4) (5) (6) (7) (8) (11) (10) (9) (12) (13) (19) (18) (20) (17) (16) (24) (10) (25) (5) (4) (4) (4) (3) (3) (3) (2) (1) (21) (15) (23) T7 T2 T2 T2 T2 T2 T2 T4 T5 T5 T8 T6 T6 T6 T11 T10 T1 T1 T3 T3 T3 T1 T9 T4 T5 T5 T3 T4 T3 T2 T4 T2 T1 T3 (20) (21) (23) (22) (10) (24) (25) (26) (35) (34) (27) (14) (28) (29) (31) (32) (37) (30) (33) (36) T3 T2 T1 :Selective part :Replacement part :Should be lubricated with grease. :Should be lubricated with oil. :Sealing point :Tightening torque .... ,

HU-4 HOW TO USE THIS MANUAL How to Use This Manual 4. SPECIFICATION If necessary, specifications are also included. 5. INSPECTION Inspections are included to be carried out before and after maintenance. 6. MAINTENANCE • Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It also describes the use of special tool, tightening torque, cautions for each procedure. • If many serviceable parts are included in one service procedure, appropriate reference are provided for each part. Example: (A) Component (D) Caution (G) Tightening torque (B) Process (E) Tool number of special tool (H) Illustration (C) Reference (F) Name of special tool HU-00002 1) Remove the manual transmission assembly from vehicie. <Ref. to MT-33, REMOVAL, Manual Transmission Assembly.> 15.Main Shaft Assembly for Sin- gle-Range A: REMOVAL 11) Tighten the lock nuts to the specified torque using ST1 and ST2. NOTE: Secure the lock nuts in two Places affer tightening. ST2 499987003 SOCKET WRENCH ST1 498937000 TRANSMISSION HOLDER (A) (B) (C) (D) (G) (E) (F) (H) Tightening torque: 118 N m (12.0 kgf-m, 86.8 ft-lb) ST1 ST2

2003-2004 Subaru Forester Service & Repair Manual

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