ECU SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 557 of 2870
CC-5
CRUISE CONTROL SYSTEM
Actuator
2. Actuator
A: REMOVAL
CAUTION:
Be careful not to apply excessive load to the
wire cable when adjusting and/or installing; oth-
erwise, the actuator may be deformed or dam-
aged.
Do not bend the cable sharply with a radius
less than 100 mm (3.94 in); otherwise, cable
may bend permanently, resulting in poor per-
formance.
When installing the cable, be careful not to
sharply bend or pinch the inner cable; other-
wise, the cable may break.
1) Disconnect the ground cable from battery.
2) Remove the clip bands from cruise control cable.
3) Loosen the nut which secures cruise control ca-
ble end to throttle cam, and then remove the cable
from throttle cam.
4) Remove the four actuator attaching bolts.
5) Remove the actuator while disconnecting the
connector.
LHD model RHD model
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
ACTUATOR:
7.4 N
⋅m (0.75 kgf-m, 5.4 ft-lb)
Cable end nut:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
NOTE:
(A): Must be adjusted when the cable end outer is
fixed in place, so that gap between throttle cam and
lever is 0 — 1 mm (0 — 0.04 in), otherwise, inner
cable deflection (D) is 1 — 8 mm (0.039 — 0.315 in)
when the throttle cable is installed.
(Must be attached while the throttle cam is being
pulled by wire cable.)
(B): Must be coated evenly on the cam end inner
connection.
(C): Cover must be inserted securely, until tip of ca-
ble touches cover stopper.
CC-00009
CC-00010
CC-00070
CC-00037
(B)
(A) (D) (C)
Page 561 of 2870
CC-9
CRUISE CONTROL SYSTEM
Cruise Control Command Switch
5. Cruise Control Command
Switch
A: REMOVAL
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the driv-
er’s airbag module.
1) Set the front wheels in straight ahead position.
2) Turn the ignition switch to OFF.
3) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
4) Using the TORX
® BIT T30 (Tamper resistant type),
loosen the two TORX® bolts which secure driver’s air-
bag module.
5) Disconnect the airbag module connector on
back of airbag module.
6) Remove the horn switch from steering wheel as
shown.7) Disconnect the horn and cruise control com-
mand switch connector, then remove the cruise
control command switch.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure the cruise control command switch resis-
tance.
If NG, replace the cruise control command switch.
(1)
TORX® BIT T30
CC-00018
(1)
CC-00019
Switch Position Terminal No. Standard
CANCELON 1 (+) and 2 (−) Less than 1 Ω
ON 1 (+) and 3 (−) Less than 1 Ω
SET/COASTOFF 1 and 2 More than 1 MΩ
ON 1 and 2 Less than 1 Ω
RESUME/
ACCELOFF 1 and 3 More than 1 MΩ
ON 1 and 3 Less than 1 Ω
CC-00020
CC-00038
1 2 3
Page 567 of 2870
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
Page 573 of 2870
CC(H4SO)-5
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
General Description
C: INSPECTION
1. BATTERY
Measure the battery voltage and specific gravity of
electrolyte.
Standard voltage:
12 V, or more
Specific gravity:
Above 1.260
2. CRUISE CONTROL CABLE
1) Check the cruise control cable installation.
2) If NG, install the cable securely.
3. ACCELERATOR CABLE
1) Check the movement of accelerator cable when
the cruise control throttle is moved by hand.
2) If NG, check the throttle cam.
4. THROTTLE CAM
Check that the throttle cam moves smoothly.
If NG, repair the throttle cam.
5. CABLE FREE PLAY
1) Check that the throttle cam-to-lever clearance
(A) or cable (B) deflection amount (D) is within
specifications.
Throttle cam-to-lever clearance:
0 — 1 mm (0 — 0.04 in)
Inner cable deflection:
1 — 8 mm (0.04 — 0.31 in)
2) If NG, adjust the clearance with the adjusting
nut.
NOTE:
Check that the cap (C) is positioned in the groove.
(1) Cruise control cable
(1) Accelerator cable
CC-00043
(1)
CC-00044
(1)
CC-00037
(B)
(A) (D) (C)
Page 593 of 2870
CC(H4SO)-25
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Symptom
H: CHECK INHIBITOR SWITCH (AT MODEL)
TROUBLE SYMPTOM:
Cruise control cannot be set.
WIRING DIAGRAM:
CC-00254
B94T7B12B323
12345678910
11 12 13 14 15 16 17 18 19 20123
4
56
78
9
1011 12
B94
B323
B12
T3
T7
B14
CRUISE
CONTROL
MODULE
INHIBITOR
SWITCH (AT MODEL)STARTER
MOTOR
4
1211
127
WS
WS
WS
OS
OS
123456789101112
:WITHOUT SECURITY SYSTEM
:WITH SECURITY SYSTEM
TO SECURITY
SYSTEM
3412
OS
BATTERY
SBF-1M/B No.2
SECURITY RELAY
2134
Page 607 of 2870
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
Page 611 of 2870
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
Page 641 of 2870
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
Page 687 of 2870
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.
15.Main Shaft Assembly for Sin-
gle-Range
A: REMOVAL
11) Tighten the lock nuts to the specified torque us-
ing 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)
ST1ST2
Page 694 of 2870
SPC-5
SPECIFICATION
Forester
J: WEIGHT
1. LHD MODEL
★: For the option codes, refer to ID section.
★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 — — — — — —