Subaru Forester SG Service Manual / Repair Manual View larger

Subaru Forester SG Service Manual / Repair Manual

English Service Manual / Repair Manual to vehicles Subaru Forester SG (1999-2004).

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LANGUAGE: English.
FORMAT: PDF file
PAGES: 6016
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SUBARU FORESTER SG - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual to vehicles Subaru Forester SG (1999-2004).

 
CONTENTS:


01 - GENERAL INFORMATION SECTION
 
- Foreword
- How to use this manual
- Identification
- Note
- Precaution
- Pre-delivery inspection
- Recommended materials
- Specifications

02 - PERIODIC MAINTENANCE SERVICES
 
- Air Cleaner Element
- ATF
- Axle Boots & Joints
- Brake Fluid
- Brake Line
- Brake Linings and Drums
- Clutch System

- Coolant
- Cooling System
- Disc Brake Pads and Discs
- Engine Oil Filter
- Engine Oil
- Front & Rear Differential Oil
- Fuel Filter
- Fuel Line
- General Description
- Hill-holder System
- Schedule
- Spark Plugs
- Steering System (Power Steering)
- Supplemental Restraint System
- Suspension
- Timing Belt
- Tire Rotation
- Transmission Gear Oil
- V-belt
- Wheel Bearing

03 - ENGINE SECTION (H4DOTC)
 
- Accelerator Pedal
- Air By-pass Valve
- Air Cleaner
- Air Intake Duct
- Basic Diagnostic Procedure
- Cam Sprocket
- Camshaft Position Sensor
- Camshaft
- Center Exhaust Pipe
- Check List for Interview
- Clear Memory Mode
- Compression
- Compulsory Valve Operation Check Mode
- Connecting Rod
- Crank Pulley
- Crank Sprocket
- Crankshaft Position Sensor
- Crankshaft
- Cylinder Block
- Cylinder Head Assembly
- Data Link Connector
- Diagnostic Procedure with Diagnostic Trouble Code (DTC)
- Diagnostic Trouble Code (DTC) Detecting Criteria
- Diagnostics for Engine Starting Failure
- Drain Filter
- Drain Valve
- Drive Cycle
- Electrical Components Location
- Engine Assembly
- Engine Condition Data
- Engine Control Module (ECM) IO Signal
- Engine Control Module (ECM)
- Engine Coolant Temperature Sensor
- Engine Mounting
- Engine Noise
- Engine Oil Pressure
- Engine Trouble in General
- Exhaust Temperature Sensor
- Front Catalytic Converter
- Front Exhaust Pipe
- Front Oxygen (AF) Sensor
- Fuel Cut Valve
- Fuel Damper Valve
- Fuel Delivery, Return and Evaporation Lines
- Fuel Filler Pipe
- Fuel Filter
- Fuel Injector
- Fuel Level Sensor
- Fuel Pressure
- Fuel Pump Control Unit
- Fuel Pump Relay
- Fuel Pump
- Fuel Sub Level Sensor
- Fuel System Trouble in General
- Fuel Tank Pressure Sensor
- Fuel Tank Sensor Control Valve
- Fuel Tank
- Fuel Temperature Sensor
- Fuel
- General Diagnostic Table
- Idle Speed
- Ignition Coil & Ignitor ASSY
- Ignition Timing
- Inspection Mode
- Intake and Exhaust Valve
- Intake Duct
- Intake Manifold Vacuum
- Intake Manifold
- Intercooler
- Joint Pipe
- Knock Sensor
- List of Diagnostic Trouble Code (DTC)
- Main Relay
- Malfunction Indicator Light
- Manifold Absolute Pressure Sensor
- Mass Air Flow and Intake Air Temperature Sensor
- Muffler
- OBD-II General Scan Tool
- PCV Hose Assembly
- Piston
- Precatalytic Converter
- Preparation for Overhaul
- Pressure Control Solenoid Valve
- Purge Control Solenoid Valve
- Read Diagnostic Trouble Code (DTC)
- Rear Catalytic Converter
- Rear Exhaust Pipe
- Rear Oxygen Sensor
- Resonator Chamber
- Shut Valve
- Spark Plug
- Subaru Select Monitor
- Throttle Body
- Timing Belt Assembly
- Timing Belt Cover
- Tumble Generator Valve Actuator
- Tumble Generator Valve Assembly
- Turbocharger
- V-belt
- Vent Valve
- Wastegate Control Solenoid Valve
 
04 - ENGINE SECTION (H4SO)
 
- Accelerator Control Cable
- Accelerator Pedal
- Air Assist Injector Solenoid Valve
- Air Cleaner Case
- Air Cleaner Element
- Air Intake Duct
- Basic Diagnostic Procedure
- Battery
- Cam Sprocket
- Camshaft Position Sensor
- Camshaft
- Canister
- Center Exhaust Pipe
- Check List for Interview
- Clear Memory Mode
- Compression
- Compulsory Valve Operation Check Mode
- Coolant Filler Tank
- Crank Pulley
- Crankshaft Position Sensor
- Crankshaft Sprocket
- Cylinder Block
- Cylinder Head Assembly
- Data Link Connector
- Diagnostic Procedure with Diagnostic Trouble Code (DTC)
- Diagnostic Trouble Code (DTC) Detecting Criteria
- Diagnostics for Engine Starting Failure
- Drain Filter
- Drain Valve
- Drive Cycle
- EGR Valve
- Electrical Components Location
- Engine Assembly
- Engine Condition Data
- Engine Control Module (ECM) IO Signal
- Engine Control Module (ECM)
- Engine Coolant Temperature Sensor
- Engine Coolant
- Engine Cooling System Trouble in General
- Engine Lubrication System Trouble in General
- Engine Mounting
- Engine Noise
- Engine Oil Cooler
- Engine Oil Filter
- Engine Oil Pressure
- Engine Oil
- Engine Trouble in General
- Front Catalytic Converter
- Front Exhaust Pipe
- Fuel Cut Valve
- Fuel Damper Valve
- Fuel Delivery, Return and Evaporation Lines
- Fuel Filler Pipe
- Fuel Filter
- Fuel Injector
- Fuel Level Sensor
- Fuel Pressure
- Fuel Pump Relay
- Fuel Sub Level Sensor
- Fuel System Trouble in General
- Fuel Tank Pressure Sensor
- Fuel Tank Sensor Control Valve
- Fuel Tank
- Fuel Temperature Sensor
- Fuel
- General Diagnostic Table
- Generator
- Idle Air Control Solenoid Valve
- Idle Speed
- Ignition Timing
- Inspection Mode
- Intake Air Temperature Sensor
- Intake Manifold Vacuum
- Knock Sensor
- List of Diagnostic Trouble Code (DTC)
- Main Relay
- Malfunction Indicator Light
- Manifold Absolute Pressure Sensor
- Muffler
- OBD-II General Scan Tool
- Oil Pan and Strainer
- Oil Pressure Switch
- Oil Pressure System
- Oil Pump
- Preparation for Overhaul
- Pressure Control Solenoid Valve
- Purge Control Solenoid Valve
- Radiator Cap
- Radiator Fan System
- Radiator Main Fan and Fan Motor
- Radiator Sub Fan and Fan Motor
- Radiator
- Read Diagnostic Trouble Code (DTC)
- Rear Catalytic Converter
- Rear Exhaust Pipe
- Rear Oxygen Sensor
- Reservoir Tank
- Resonator Chamber
- Shut Valve
- Spark Plug Cord
- Spark Plug
- Starter
- Subaru Select Monitor
- Thermostat
- Throttle Position Sensor
- Timing Belt Assembly
- Timing Belt Cover
- Transmission Control Module (TCM) IO Signal
- Valve Clearance
- Valve Rocker Assembly
- V-belt
- Vent Valve
- Water Pump
 
05 - TRANSMISSION
 
- Air Bleeding of Control Valve
- Air Breather Hose
- AT OIL TEMP Warning Light Display
- AT Shift Lock Solenoid and Range Switch
- AT Shift Lock System
- AT Transmission Main Case
- ATF Charger Pipe
- ATF Cooler Pipe and Hose
- ATF Filter
- Automatic Transmission Assembly
- Automatic Transmission Fluid
- Basic Diagnostic Procedure
- Body Integrated Unit
- Center Differential
- Check List for Interview
- Clear Memory Mode
- Clutch Disc and Cover
- Clutch Fluid Air Bleeding
- Clutch Fluid
- Clutch Pedal
- Clutch Pipe and Hose
- Clutch Switch
- Control Valve Body
- Diagnostic Procedure for AT OIL TEMP Warning Light
- Diagnostic Procedure for No-diagnostic Trouble Code (DTC)
- Diagnostic Procedure for Select Monitor Communication
- Diagnostic Procedure with Diagnostic Trouble Code (DTC)
- Differential Gear Oil
- Differential Side Retainer Oil Seal
- Drive Pinion Shaft Assembly
- Drive Pinion Shaft
- Dropping Resistor
- Electrical Component
- Electrical Components Location
- Extension Case Oil Seal
- Extension Case
- Flywheel
- Front Differential Assembly
- Front Differential
- Front Vehicle Speed Sensor
- General Diagnostic Table

- Inhibitor Switch
- Inspection Mode
- Line Pressure Test
- List of Diagnostic Trouble Code (DTC)
- Main Shaft Assembly (Single-Range)
- Manual Transmission Assembly
- Master Cylinder
- MT Gear Shift Lever
- Oil Pump Housing
- Oil Seal
- Operating Cylinder
- Parking Pawl
- Preparation for Overhaul
- Read Diagnostic Trouble Code (DTC)
- Rear Vehicle Speed Sensor
- Reduction Drive Gear
- Reduction Driven Gear
- Release Bearing and Lever
- Reverse Check Sleeve
- Reverse Idler Gear
- Road Test
- Select Cable
- Select Lever
- Shift Solenoids, Duty Solenoids and ATF Temperature Sensor
- Shifter Fork and Rod
- Speedometer Gear
- Stall Test
- Subaru Select Monitor
- Switches and Harness
- Symptom Related Diagnostic
- Time Lag Test
- Torque Converter Clutch Assembly
- Torque Converter Clutch Case
- Torque Converter Turbine Speed Sensor
- Transfer Case and Extension Case Assembly
- Transfer Clutch Pressure Test
- Transfer Clutch
- Transfer Drive Gear
- Transfer Driven Gear
- Transfer Duty Solenoid and Valve Body
- Transmission Case
- Transmission Control Device
- Transmission Control Module (TCM) IO Signal
- Transmission Control Module (TCM)
- Transmission Gear Oil
- Transmission Mounting System
- Vehicle Speed Sensor

06 - CHASSIS

- ABS Control Module and Hydraulic Control Unit
- ABS Sequence Control
- ABS Warning Light Illumination Pattern
- Air Bleeding
- Aluminum Wheel
- Basic Diagnostic Procedure
- Brake Booster
- Brake Hose
- Brake Pedal
- Brake Pipe
- Center Differential
- Check List for Interview
- Clear Memory Mode
- Diagnostics Procedure with Diagnostic Trouble Code (DTC
- Diagnostics Procedure without Diagnostic Trouble Code (DTC)
- Differential Gear Oil
- Electrical Components Location
- Front ABS Wheel Speed Sensor
- Front Axle
- Front Ball Joint
- Front Brake Pad
- Front Crossmember
- Front Differential
- Front Disc Rotor
- Front Drive Shaft
- Front Stabilizer
- Front Strut
- Front Tone Wheel
- Front Transverse Link
- G Sensor
- General Diagnostic Table
- General Diagnostics Table
- General Diagnostics
- Hill Holder
- Inspection Mode
- Lateral Link
- List of Diagnostics Trouble Code (DTC)
- Master Cylinder
- Oil Pump
- Oil Seal
- Parking Brake Assembly (Rear Disc Brake)
- Parking Brake Lever
- Pipe Assembly
- Power Steering Fluid
- Propeller Shaft
- Proportioning Valve
- Read Diagnostic Trouble Code (DTC)
- Rear ABS Wheel Speed Sensor
- Rear Axle
- Rear Brake Pad
- Rear Crossmember
- Rear Differential Front Oil Seal
- Rear Differential Member
- Rear Differential Side Oil Seal
- Rear Differential
- Rear Disc Brake Assembly
- Rear Disc Rotor
- Rear Drive Shaft
- Rear Drum Brake Assembly
- Rear Drum Brake Drum
- Rear Drum Brake Shoe
- Rear Stabilizer
- Rear Strut
- Rear Tone Wheel
- Rear Trailing Link
- Reduction Drive Gear (4AT without VTD)
- Reduction Driven Gear (4AT without VTD)
- Reservoir Tank
- Steel Wheel
- Steering Gearbox
- Steering Wheel
- Sub Frame
- Subaru Select Monitor
- Tilt Steering Column
- Tire
- Transfer Clutch and Extension (4AT)
- Transfer Clutch Pressure Test
- Transfer Drive Gear (5MT)
- Transfer Driven Gear (5MT)
- Transfer Duty Solenoid and Valve Body
- Universal Joint
- Wheel Alignment
- Wheel Balancing
 
07 - BODY
 
- AC Control Module IO Signal
- Actuator
- Air Vent Grille
- Airbag Connector
- Airbag Control Module IO Signal
- Airbag Control Module
- Airbag Warning Light Failure
- Airbag Warning Light Illumination Pattern
- Ambient Sensor (Auto AC Model)
- Ambient Sensor
- Antenna Amplifier
- Antenna
- Back-up Light Bulb
- Back-up Light System
- Basic Diagnostic Procedure
- Blower Motor Unit Assembly
- Blower Resistor (Manual AC Model)
- Body Integrated Module
- Check List for Interview
- Clear Memory Mode
- Clearance Light Bulb
- Clutch Switch
- Combination Meter Assembly
- Combination Meter System
- Combination Switch (Light)
- Combination Switch (Wiper)
- Compressor Oil
- Compressor
- Condenser Fan (Sub Fan)
- Condenser
- Console Box
- Control Unit
- Cowl Panel
- Cruise Control Command Switch
- Cruise Control Main Switch
- Cruise Control Module IO Signal
- Cruise Control Module
- Datum Dimensions
- Datum Points
- Diagnostic Procedure for Actuators
- Diagnostic Procedure for Sensors
- Diagnostic Procedure with Diagnostic Trouble Code (DTC)
- Diagnostic Procedure with DTC
- Diagnostic Procedure with Symptom
- Diagnostics for AC System Failure
- Door Lock Control System
- Driver's Airbag Module
- Electrical Components Location
- Evaporator
- Floor Mat
- Front Accessory Power Supply Socket System
- Front Accessory Power Supply Socket
- Front Bumper
- Front Door Glass
- Front Door Lock Actuator
- Front Door Panel
- Front Door Trim
- Front Fender Panel
- Front Fog Light Assembly
- Front Fog Light Bulb
- Front Fog Light System
- Front Grille
- Front Hood Lock Assembly
- Front Hood Panel
- Front Inner Remote
- Front Outer Handle
- Front Regulator and Motor Assembly
- Front Sealing Cover
- Front Seat Belt
- Front Seat
- Front Speaker
- Front Sub Sensor
- Front Turn Signal Light Bulb
- Front Under Cover
- Front Washer Nozzle
- Front Wiper Arm
- Front Wiper Motor and Link
- Fuel Gauge
- General Diagnostics
- Glove Box
- Headlight and Tail Light System
- Headlight Assembly
- Headlight Bulb
- Heat Shield Cover
- Heater Cooling Unit
- Heater Core
- Heater Duct
- Heater Vent Duct
- High-mounted Stop Light
- Horn Switch
- Horn System
- Horn
- Hose and Tube
- HVAC SYSTEM (HEATER, VENTILATOR AND AC)
- Ignition Key Lock
- Inhibitor Switch (AT model)
- Inner Rearview Mirror
- Inspection Locations After a Collision
- Inspection Mode
- Instrument Panel Assembly
- Instrument Panel Center Compartment
- Interior Light System
- Interrupt Relay
- Key Lock Cylinder
- Keyless Entry Control Module
- Keyless Entry System
- Keyless Transmitter
- License Plate Light
- List of Diagnostic Trouble Code (DTC)
- List of DTC
- Lower Inner Trim
- Luggage Floor Mat
- Luggage Room Light
- Mud Guard
- Neutral Position Switch (MT model)
- Outer Mirror Assembly
- Outer Mirror
- Passenge's Airbag Module
- Power Window Control Switch
- Power Window System
- Pressure Switch (Triple Pressure Switch)
- Pretensioner Connector
- Radio Body
- Radio System
- Read Diagnostic Trouble Code (DTC)
- Rear Bumper
- Rear Combination Light Assembly
- Rear Door Glass
- Rear Door Latch Assembly
- Rear Door Lock Actuator
- Rear Door Panel
- Rear Door Trim
- Rear Gate Garnish Assembly
- Rear Gate Glass
- Rear Gate Latch Assembly
- Rear Gate Latch Lock Actuator
- Rear Gate Outer Handle
- Rear Gate Panel
- Rear Gate Trim
- Rear Inner Remote
- Rear Outer Handle
- Rear Quarter Glass
- Rear Quarter Trim
- Rear Regulator and Motor Assembly
- Rear Sealing Cover
- Rear Seat Belt
- Rear Seat
- Rear Speaker
- Rear Turn Signal Light Bulb
- Rear Washer
- Rear Window Defogger System
- Rear Window Defogger
- Rear Wiper Arm
- Rear Wiper Motor
- Refrigerant Charging Procedure
- Refrigerant Leak Check
- Refrigerant Pressure with Manifold Gauge Set
- Refrigerant Recovery Procedure
- Relay and Fuse
- Remote Control Mirror Switch
- Remote Openers
- Roll Connector
- Roof Rail
- Roof Trim
- Roof Window Glass
- Room Light
- Scalp Cap
- Security Horn Relay
- Security Horn
- Self-diagnosis
- Side Airbag Module
- Side Airbag Sensor
- Side Garnish
- Side Marker Light Bulb
- Side Sill Spoiler
- Speedometer
- Spot Map Light
- Stop and Brake Switch
- Stop Light System
- Subaru Select Monitor
- Sun Visor
- Sun-load Sensor (Auto AC Model)
- Sunroof Assembly
- Sunroof Control System
- Sunroof Lid
- Sunroof Motor
- Sunroof Switch
- Symptom Related Diagnostic
- Tachometer
- Tail Stop Light Bulb
- Turn Signal and Hazard Light System
- Tweeter
- Upper Inner Trim
- Washer Tank and Motor
- Water Temperature Gauge
- Windshield Glass
- Wiper and Washer System
- Wiper Blade
- Wiper Control Relay
- Woofer

08 - WIRING SYSTEM

- Air Conditioning System
- Airbag System
- Anti-lock Brake System
- AT Control System
- AT Shift Lock Control System
- Audio System
- Back-up Light System
- Basic Diagnostics Procedure
- Bulkhead Wiring Harness (In Compartment)
- Bulkhead Wiring Harness (In Engine Room)
- Charging System
- Clearance Light and Illumination Light System
- Clock System
- Combination Meter
- Compass Mirror System
- Cruise Control System
- Door Cord
- Door Lock System
- Engine Coolant Temperature Gauge System
- Engine Electrical System
- Engine Wiring Harness and Transmission Cord
- Front Accessory Power Supply System
- Front Fog Light System
- Front Wiring Harness
- Fuel Gauge System
- Ground Distribution
- Harness Components Location
- Headlight System
- Horn System
- In Compartment Light System
- Instrument Panel Wiring Harness
- Keyless Entry System
- Oil Pressure Warning Light System
- Outside Temperature Display System
- Parking Brake and Brake Fluid Level Warning System
- Power Supply Routing
- Power Window System
- Radiator Fan System
- Rear Accessory Power Supply System
- Rear Window Defogger System
- Rear Wiring Harness and Rear Gate Cord
- Rear Wiring Harness, Bulkhead Wiring Harness, Roof Cord
- Remote Controlled Rearview Mirror System
- Seat Belt Warning System
- Seat Heater System
- Security System
- Starter System
- Stop Light System
- Sunroof System
- Turn Signal Light and Hazard Light System
- Wiper and Washer System (Front)
- Wiper and Washer System (Rear)
- Wiper Deicer System
- Working Precautions
 
09 - DIAGNOSTIC TROUBLE CODE
 
- GD (H4DOTC) - Diagnostic Trouble Code (DTC) Detecting Criteria
- GD (H4DOTC) - List of Diagnostic Trouble Code (DTC)
- GD (H4SO) - Diagnostic Trouble Code (DTC) Detecting Criteria
- GD (H4SO) - List of Diagnostic Trouble Code (DTC)