clutch SUBARU FORESTER 1999 Service Repair Manual

C: ELECTRICAL COMPONENTS LOCATION
S6M0106A
(1) Actuator (with valves)
(2) Inhibitor switch (AT)
(3) Cruise control main switch(4) Cruise control command switch
(5) Cruise control module
(6) Stop and brake switch(7) Clutch switch (MT)
18
6-2[T3C0]DIAGNOSTICS
3. Cruise Control System

E: CONTROL MODULE I/O SIGNAL
G6M0015
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Vent valve 1IPower supply is ON when vehicle is stopped.
ION-and-OFF (ª0º-and-battery voltage) operation is alternately repeated while
cruise control is operating.
Safety valve 2IPower supply is ON when vehicle is stopped.
ION-and-OFF (ª0º-and-battery voltage) operation is alternately repeated while
cruise control is operating.
Ignition switch 3IBattery voltage is present when ignition switch is turned ON.
Iª0º volt is present when ignition switch is turned OFF.
Cruise control main switch 4IBattery voltage is present when main power is turned ON.
Iª0º volt is present when main power is turned OFF.
Power supply to vacuum valve,
vent valve, safety valve and
indicator light5IBattery voltage is present when main power is turned ON.
Iª0º volt is present when main power is turned OFF.
SET/COAST switch 6IBattery voltage is present when command switch is turned to SET/COAST
position.
Iª0º volt is present when command switch is released.
RESUME/ACCEL switch 7IBattery voltage is present when command switch is turned to RESUME/
ACCEL position.
Iª0º volt is present when command switch is released.
Brake switch 8 Set select lever to any position other than ªPº or ªNº position (AT) / leave
clutch pedal released (MT), while cruise control main switch is turned ON.
Then check that;
IBattery voltage is present when brake pedal is released.
Iª0º volt is present when brake pedal is depressed, or
IBattery voltage is present when clutch pedal is released (MT).
Iª0º volt is present when clutch pedal is depressed (MT).
IBattery voltage is present when select lever is in any position other than ªPº
or ªNº position (AT).
Iª0º volt is present when select lever is set to ªPº or ªNº position (AT).
Clutch switch (MT)/
Inhibitor switch (AT)9IBattery voltage is present when clutch pedal is released (MT).
Iª0º volt is present when clutch pedal is depressed (MT).
IBattery voltage is present when select lever is in any position other than ªPº
or ªNº position (AT).
Iª0º volt is present when select lever is set to ªPº or ªNº position (AT).
Vacuum valve 11IPower supply is ON when vehicle is stopped.
ION-and-OFF (ª0º-and-battery voltage) operation is alternately repeated while
cruise control is operating.
Set signal to transmission con-
trol module (AT)12ITCM emits a ground-level signal while driving vehicle at least 40 km/h (25
MPH) with SET switch ON.
Ground 13 Ð
Check connector/
OBD-II service connector14 Ð
Check connector/
OBD-II service connector15 Ð
20
6-2[T3E0]DIAGNOSTICS
3. Cruise Control System

F: DIAGNOSTICS CHART FOR ON-
BOARD DIAGNOSIS SYSTEM
1. BASIC DIAGNOSTIC PROCEDURE
3F11 : CHECK CRUISE CONTROL MAIN
SWITCH.
1) Trouble occurs.
2) Perform pre-inspection.
3) Check cruise control main switch.
:Does cruise control main switch turn
ON?
: Go to step3F12.
: Go to ªDiagnostics Chart for Power
Lineº.
3F12 : CHECK CRUISE SPEED IS SET.
:Does cruise speed properly set while
driving at minimum of 40 km/h (25
MPH)?
: Go to step3F13.
: Go to ªDiagnostics Chart with Trouble
Codeº.
3F13 : CHECK CRUISE CONTROL IS
RELEASED.
:Does cruise control properly release
during operation?
: Go to step3F14.
: Go to ªDiagnostics Chart with Trouble
Codeº.
3F14 : CHECK CRUISE SPEED IS HELD
WITHIN SET SPEED.
:Does cruise speed hold within set
speed
±3 km/h (2 MPH)?
: Go to step3F15.
: Go to pre-inspection of actuator. to 6-2 [T3B4].>
3F15 : CHECK RESUME/ACCEL SWITCH.
:Does RESUME/ACCEL switch func-
tion properly?
: Go to step3F16.
: Go to ªDiagnostics Chart with Trouble
Codeº. 3F16 : CHECK SET/COAST SWITCH.
:Does SET/COAST switch function
properly?
: Go to step3F17.
: Go to ªDiagnostics Chart with Trouble
Codeº.
3F17 : CHECK CANCEL SWITCH.
:Does CANCEL switch function prop-
erly?
: Go to step3F18.
: Go to ªDiagnostics Chart with Trouble
Codeº.
3F18 : CHECK CRUISE SPEED IS
RELEASED.
:Does cruise speed release when
brake pedal is depressed?
: Go to step3F19.
: Go to ªDiagnostics Chart with Trouble
Codeº.
3F19 : CHECK CRUISE SPEED IS
RELEASED.
:Does cruise speed release when
clutch pedal is depressed?
: Cruise control system is in correct order.
: Go to ªDiagnostics Chart with Trouble
Codeº.
22
6-2[T3F1]DIAGNOSTICS
3. Cruise Control System

2. ON-BOARD DIAGNOSIS WITH SELECT
MONITOR
IGeneral
The on-board diagnosis function of the cruise con-
trol system uses an external select monitor.
The on-board diagnosis function operates in two
categories, which are used depending on the type
of problems;
NOTE:
Select monitor part No.:

1) Cruise cancel conditions diagnosis
(1) This category of diagnosis requires actual
vehicle driving in order to determine the cause,
(as when cruise speed is cancelled during driv-
ing although cruise cancel condition is not
entered).
(2) Cruise control module memory stores the
cancel condition (Code No.) which occurred
during driving. When there are plural cancel
conditions (Code No.), they are shown on the
select monitor.
CAUTION:
IThe cruise control memory stores not only
the cruise ªcancelº which occurred (although
ªcancelº operation is not entered by the
driver), but also the ªcancelº condition input by
the driver.
IThe content of memory is cleared when igni-
tion switch or cruise main switch is turned OFF.
2) Real-time diagnosis
The real-time diagnosis function is used to deter-
mine whether or not the input signal system is in
good order, according to signal emitted from
switches, sensors, etc.
(1) Vehicle cannot be driven at cruise speed
because problems occurs in the cruise control
system or its associated circuits.
(2) Monitor the signal conditions from switches
and sensors.
ICruise Cancel Conditions Diagnosis
1) Connect select monitor.
2) Start the engine and turn cruise control main
switch to ON.
3) Set select monitor in ªAll System Diagnosisº
mode.
NOTE:
The diagnostic code is also shown in the ªEach
System Checkº mode. This mode is called up on
the ªCruise Control Diagnosisº screen by selecting
the item ªCancel Code(s) Displayº.
4) Drive vehicle at least 40 km/h (25 MPH) with
cruise speed set.5) If cruise speed is canceled itself (without doing
any cancel operations), a diagnostic code will
appear on select monitor display.
CAUTION:
IA diagnostic code will also appear when
cruise cancel is effected by driver. Do not con-
fuse.
IHave a co-worker ride in vehicle to assist in
diagnosis during driving.
NOTE:
Diagnostic code will be cleared by turning ignition
switch or cruise control main switch to OFF.
IReal-Time Diagnosis
1) Connect select monitor.
2) Turn ignition switch and cruise control main
switch to ON.
3) Select the ªCurrent Data Display & Saveº mode
on the select monitor ªCruise Control Diagnosisº
screen.
4) Ensure that normal indication is displayed when
controls are operated as indicated below:
IDepress/release the brake pedal. (Stop light
switch and brake switch turn ON.)
ITurn ON the ªSET/COASTº switch.
ITurn ON the ªRESUME/ACCELº switch.
IDepress/release the clutch pedal. (MT)
ISet the select lever to P or N. (AT)
23
[T3F2]6-2DIAGNOSTICS
3. Cruise Control System

H: DIAGNOSTICS CHART WITH DIAGNOSTIC CODE
1. DIAGNOSTIC CODE LIST
Diagnostic
codeItem Contents of diagnosis Index No.
11 BRAKE SW/STOP SW Input signals from brake switch ªOFFº, stop light
switch ªONº
(Brake pedal is depressed.)
12 CLUTCH SW/INHIBITOR SW Input signals from clutch switch ªOFFº (MT), or inhibi-
tor switch ªP or Nº (AT)
[Clutch pedal is depressed (MT), or select lever is set
to P or N position (AT).]
13 LOW SPEED LIMIT Low-speed control limiter
14 CANCEL SW Input signal from cancel switch
(faulty SET/COAST switch or RESUME/ACCEL
switch)
21 VACUUM VALVE Faulty vacuum valve or valve drive system
22 VENT 2 VALVE Faulty vent 2 valve or valve drive system
23 VENT 1 VALVE Faulty vent 1 valve or valve drive system
24 SPEED SENSOR Faulty vehicle speed sensor (MT) or transmission
control module (AT)
25 CONTROL MODULE Faulty CPU RAM included in cruise control module
29
[T3H1]6-2DIAGNOSTICS
3. Cruise Control System

3. DIAGNOSTIC CODE 12 (CLUTCH SWITCH, INHIBITOR SWITCH)
DIAGNOSIS:
IFailure or disconnection of the clutch switch. (MT)
IFailure or disconnection of the inhibitor switch. (AT)
TROUBLE SYMPTOM:
ICruise control cannot be set.
WIRING DIAGRAM:
S6M0384
34
6-2[T3H3]DIAGNOSTICS
3. Cruise Control System

3H31 : CHECK CLUTCH SWITCH. (MT)
1) Turn ignition switch to ON.
2) Turn cruise control main switch to ON.
3) Apply parking brake securely.
4) Set select monitor in ªCurrent Data Display &
Saveº mode.
5) Depress the clutch pedal and check signal for
proper operation. (MT)
The Clutch/Inhibitor Switch shown on the display
turns from ªONº to ªOFFº.
6) Disconnect connector of clutch switch.
7) Check continuity of the clutch switch.
Terminals
No. 1 Ð No. 2:
G6M0184
:Is resistance less than 10W? (When
clutch pedal is released.)
: Go to step3H32.
: Replace clutch switch. [C100].>3H32 : CHECK CLUTCH SWITCH. (MT)
Check continuity of the clutch switch.
Terminals
No. 1 Ð No. 2:
G6M0184
:Is resistance more than 1 MW? (When
clutch pedal is depressed.)
: Replace cruise control module. 6-2 [W12B4].>
: Replace clutch switch. [C100].>
35
[T3H3]6-2DIAGNOSTICS
3. Cruise Control System

3H33 : CHECK INHIBITOR SWITCH. (AT)
1) Turn ignition switch to ON.
2) Turn cruise control main switch to ON.
3) Apply parking brake securely.
4) Set select monitor in ªCurrent Data Display &
Saveº mode.
5) Set the select lever from P or N position to D
position and check signal for proper operation.
The Clutch/Inhibitor Switch shown on the display
turns from ªONº to ªOFFº.
6) Set the select lever to P or N position.
7) Disconnect connector of inhibitor switch.
8) Check continuity of the inhibitor switch.
Terminals
No. 7 Ð No. 12:
B6M1426
:Is resistance less than 10W? (When
select lever is in P or N.)
: Go to step3H34.
: Replace inhibitor switch. [W200].> Repair inhibitor switch wiring
harness.3H34 : CHECK INHIBITOR SWITCH. (AT)
Check continuity of the inhibitor switch.
Terminals
No. 7 Ð No. 12:
B6M1426
:Is resistance more than 1 MW? (When
select lever is not in P or N.)
: Replace cruise control module. 6-2 [W12B4].>
: Replace inhibitor switch. [W200].> Repair inhibitor switch wiring
harness.
36
6-2[T3H3]DIAGNOSTICS
3. Cruise Control System

7. DIAGNOSTIC CODE 25 (CRUISE
CONTROL MODULE BUILT-IN RELAY,
CPU RAM)
DIAGNOSIS:
IPoor welding of built-in relay of cruise control
module.
IFailure of built-in CPU RAM of cruise control
module.
TROUBLE SYMPTOM:
ICruise control is canceled and memorized
cruise speed is also canceled.
IOnce cruise control is canceled, cruise control
cannot be set until the ignition switch and cruise
control main switch turns OFF, and then turns ON
again.
NOTE:
Check input/output signal and vehicle speed signal
with select monitor. When signals are in good
condition, failure is in cruise control module.
(Check power supply and ground conditions of
cruise control module.)
I: DIAGNOSTICS CHART WITH
SELECT MONITOR
1. FUNCTION MODE
NOTE:
Select monitor part No.:

Select the ªCruise Controlº system using the select
monitor and set the ªCurrent Data Display & Saveº
mode. The following parameters will then appear
on the display.
IVehicle Speed
The current vehicle speed is shown on the display.
IStop Light Switch
When the brake pedal is depressed, the stop light
switch shown on the display turns from ªOFFº to
ªONº.
IBrake Switch
When the brake pedal is depressed, the brake
switch shown on the display turns from ªOFFº to
ªONº.
IªSET/COASTº Switch
When the cruise control command switch is placed
in the ªSET/COASTº position, the SET/COAST
switch shown on the display turns from ªOFFº to
ªONº.
IªRESUME/ACCELº Switch
When the cruise control command switch is placed
in the ªRESUME/ACCELº position, the RESUME/
ACCEL switch shown on the display turns from
ªOFFº to ªONº.
IClutch/Inhibitor SwitchWhen the clutch pedal is depressed, the clutch/
inhibitor switch shown on the display turns from
ªONº to ªOFFº. (MT)
When the select lever is moved from the ªNº or ªPº
position to any other position, the clutch/inhibitor
switch shown on the display turns from ªONº to
ªOFFº.
52
6-2[T3H7]DIAGNOSTICS
3. Cruise Control System

5. DIAGNOSTICS ITEM 4
5F51 : CHECK INPUT SIGNAL FOR
STARTER MOTOR.
1) Disconnect connector from starter motor.
2) Turn ignition switch to START.
3) Measure voltage between starter motor con-
nector (B14) and engine ground.
Connector & terminal
(B14) No. 1 (+) Ð Engine ground (þ):
OBD0100A
NOTE:
IOn AT vehicles, place the select lever in the P
or N position.
IOn MT vehicles, depress the clutch pedal.
:Is the voltage more than 10 V?
: Go to step5F52.
: Go to step5F53.
5F52 : CHECK GROUND CIRCUIT OF
STARTER MOTOR.
1) Turn ignition switch to OFF.
2) Disconnect terminal from starter motor.
3) Measure resistance between ground cable ter-
minal and engine ground.
:Is the resistance less than 5W?
: Check starter motor. [W100].>
: Repair or replace ground cable.
5F53 : CHECK FUSE.
Remove and visually check the fuse SBF-1 (in
main fuse box).
:Is fuse SBF-1 blown?
: Replace SBF fuse (80 A).
: Go to step5F54.5F54 : CHECK FUSE.
Remove and visually check the fuse SBF-4 (in
main fuse box).
:Is fuse SBF-4 blown?
: Replace SBF fuse (50 A).
: Go to step5F55.
5F55 : CHECK INTERRUPT RELAY.
1) Turn ignition switch to OFF.
2) Remove interrupt relay (behind the fuse box).
S6M0469
3) Check continuity between interrupt relay termi-
nals.
Terminals
No. 1 Ð No. 4:
B6M0992
:Does continuity exist?
: Go to step5F56.
: Replace interrupt relay.
84
6-2[T5F5]DIAGNOSTICS
5. Security System