SUBARU FORESTER 2004 Service Repair Manual

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

2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G8080GE7
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)CC(H4SO)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)CC(H4DOTC)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)CC(H4DOTC 2.5)
IMMOBILIZER (DIAGNOSTIC) IM

AIRBAG SYSTEM (DIAGNOSTIC)
AB
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview ...............................................................................3
3. General Description ....................................................................................4
4. Electrical Components Location................................................................19
5. Airbag Control Module I/O Signal..............................................................21
6. Airbag Connector ......................................................................................27
7. Airbag Warning Light Illumination Pattern .................................................30
8. Read Diagnostic Trouble Code (DTC) ......................................................31
9. Inspection Mode ........................................................................................32
10. Clear Memory Mode..................................................................................33
11. Airbag Warning Light Failure.....................................................................34
12. List of Diagnostic Trouble Code (DTC) .....................................................43
13. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................46

AB-2
AIRBAG SYSTEM (DIAGNOSTIC)
Basic Diagnostic Procedure
1. Basic Diagnostic Procedure
A: PROCEDURE
Step Check Yes No
1 READ DTC.
(DTC).>Is the normal code detected? Finish the diagno-
sis.Go to step 2.
2 READ DTC.
(DTC).>Is DTC displayed? Go to step 3.Replace the airbag
warning light.
Airbag Warning
Light Failure.>
3 PERFORM THE DIAGNOSIS.
1) Judge the possible cause from “List of
Diagnostic Trouble Code (DCT)” 43, List of Diagnostic Trouble Code (DTC).>
2) Inspect using “Diagnostic Procedure with
Diagnostic Trouble Code (DTC)”.
3) Repair the cause of the trouble.
4) Perform the clear memory mode. AB-33, Clear Memory Mode.>
5) Perform the inspection mode. 32, Inspection Mode.>
6) Read any DTC again.Is DTC displayed? Perform the proce-
dure 1) to 5) in
step 3.Finish the diagno-
sis.

AB-3
AIRBAG SYSTEM (DIAGNOSTIC)
Check List for Interview
2. Check List for Interview
A: CHECK
Customer’s Name Inspector’s Name
Date Vehicle Brought In / / Registration No.
Odometer Readingkm
milesVIN
Date Problem Occurred / / Registration Year / /
Weather❏ Fine ❏ Cloudy ❏ Rainy ❏ Snowy ❏ Other:
Temperature°C (°F)
Road Condition❏ Level road❏ Uphill ❏ Downhill❏ Rough road ❏ Others:
Vehicle Operation❏ Starting❏ Idling
❏ Driving (❏ Constant speed❏ Acceleration❏ Deceleration
❏ Steering wheel turn❏ Others: )
Details of Problem
Check Airbag Warning Light❏ Normal (After turning the ignition switch to ON, lit for 7 seconds and goes off.)
❏ Remains ON❏ Remains OFF
Check DTC❏ Normal Code❏ DTC: (Code: )

AB-4
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
3. General Description
A: CAUTION
 When servicing a vehicle, be sure to turn the ig-
nition switch to OFF, disconnect the ground cable
from battery, and wait for more than 20 seconds
before starting work.
 The airbag system is fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground cable is disconnected, it
may inflate.
 If sensors, airbag module, airbag control module,
pretensioner, and harness are deformed or dam-
aged, replace them with new genuine parts.
 Do not use the airbag system and pretensioners
on other vehicles. When replacing parts, be sure to
replace them with new parts.
 When checking the system, be sure to use a dig-
ital circuit tester. Use of an analog circuit tester may
cause the airbag to activate erroneously. When checking, use a test harness. Do not di-
rectly apply the tester probe to any connector termi-
nal of the airbag.
 Do not drop the airbag modulator parts, subject
them to high temperature over 93°C (199°F), or let
water, oil, or grease get on them; otherwise, the in-
ternal parts may be damaged and reliability greatly
lowered.
AB-00002
AB-00120
AB-00121
(1) Test harness
AB-00122
(1)
AB-00123

AB-5
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
 If any damage, opening, or rust is found on the
airbag system wiring harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
 Install the wiring harness securely with the spec-
ified clips to avoid interference or tangled up with
other parts.
 Do not allow water or oil to come in contact with
the connector terminals. Do not touch the connec-
tor terminals. Either of the airbag modules for driver, passen-
ger or side, or pretensioner must not be disassem-
bled.
 The airbag module cannot be used again once
inflated.
 After removal, keep the airbag module with the
pad facing upward on a dry, clean, and flat surface
away from heat and light sources, and moisture
and dust.
 Do not check continuity of either of the airbag
modules for driver, passenger or side, or preten-
sioner.
AB-00124
AB-00125
AB-00126
AB-00127
AB-00056
AB-00006

AB-6
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
 The removed front seat with the airbag module
must be kept at least 200 mm (8 in) away from walls
and other objects.
 When painting or performing sheet metal work
on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame, re-
move the front sub sensors and wire harness of the
airbag system.
 When painting or performing sheet metal work
on the side of the vehicle, including the side sill,
center pillar, and front and rear doors, remove the
side airbag sensors and wiring harness of the air-
bag system.
 Do not discard undeployed airbag modules.
They could easily cause a serious accident if acci-
dentally deployed.
(1) More than 200 mm (8 in)
AB-00128
(1)
AB-00129

AB-7
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
 When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of
each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under
any object, a serious accident may result.
(1) Driver side airbag module (2) Passenger side airbag module
AB-00130
(2) (1)

AB-8
AIRBAG SYSTEM (DIAGNOSTIC)
General Description
B: INSPECTION
Before diagnosing, check the following items that might be related to the engine problem:
1. BATTERY
Measure the battery voltage and specific gravity of electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260
C: PREPARATION TOOL
1. SPECIAL TOOL
 TEST HARNESS M
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
98299FE020 TEST HARNESS M  Used when measuring voltage, resistance of
airbag system.
 Used with test harness T (98299SA060).
5M3M 4M
1M
2M
ST98299FE020
AB-00425
5M
1
21
Lg
2
8
18
5
16
7
6
9
1
11
10
4
2
Lg
YL
Y
100
GW
3M 4M
1M
2M
12
65 21
4334 12
56 21 1
234 5678
91011
12 13 14 15 16 17 18
1
2
3
4
5
6
2M 1M 4M 3M
5M6
5
4
3
2
1