replace SUBARU FORESTER 2004 Service User Guide

AC-49
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Heater Cock Solenoid Valve
24.Heater Cock Solenoid Valve
A: REMOVAL
1) Drain the engine coolant.
COOLANT, REPLACEMENT, Engine Coolant.>
2) Remove the battery.
3) Remove the two bolts and disconnect harness
connector, and move the washer tank forward.
4) Disconnect the harness connector (A) of the
heater cock solenoid valve.
5) Remove the two bolts to remove the heater cock
solenoid from the bracket.
6) Pull out the heater cock solenoid. Loosen the
hose clamp and disconnect the two heater hoses.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Remove the heater cock solenoid valve. AC-49, REMOVAL, Heater Cock Solenoid Valve.>
2) Connect the positive terminal of battery to No. 1
terminal of heater cock solenoid valve, and the
ground terminal to No. 2 terminal. Check that the
heater cock solenoid valve opens and closes nor-
mally.
If any failure is found, replace the heater cock sole-
noid valve.
WW-00011
AC-00886
(A)
AC-00887
1 2
AC-00888

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

AC-10
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Chart for Self-Diagnosis
Step Check Yes No
1 SELECT CONTROL PANEL TO SELF-DIAG-
NOSIS MODE.
1) Turn the ignition switch to OFF.
2) Start the engine while pressing defroster
switch and A/C switch.
N
OTE:
Self-diagnosis can also be performed with the
ignition switch ON, but start the engine be-
cause telling the magnet clutch operation is dif-
ficult.
3) The LED in A/C control panel blinks.Does the self-diagnosis mode
operate?Go to step 2. C OR SELF-DIAG-
NOSIS SYS-
TEMS DO NOT
OPERATE, Diag-
nostics for A/C
System Malfunc-
tion.>
2 CHECK LED ILLUMINATION.
Make sure that three LED blink in turn on A/C
control panel (5 patterns are repeated 2 times).Do all LED blink? Go to step 3.Go to step 5.
3 CHECK SENSORS MALFUNCTION.
1) After completing the LED check or when
AUTO switch is pressed, the A/C switch LED
illuminates, and then the sensor check is
started.
2) Check the input signal of each sensor in
turn. If there are any trouble for each sensor,
DEF, MODE and fan speed LEDs are blinked.
Also check for each sensor is possible respec-
tively every time AUTO switch is pressed. (At
this time, the AUTO switch LED illuminates.)
3) If there is no trouble, DEF, MODE and fan
speed LEDs are turned off.
N
OTE:
Rear window defogger LED illuminates in case
of stored malfunction but does not illuminate in
case of present malfunction.Does each DEF, MODE and
fan speed LED turn off?Go to step 4.Confirm the com-
bination of illumi-
nating LEDs by
using Sensor
Check Table, and
identify the mal-
functioning sensor
before repairing.
SENSOR CHECK
TABLE, OPERA-
TION, Diagnostic
Chart for Self-
Diagnosis.>
4 CHECK OPERATION OF EACH ACTUATOR,
COMPRESSOR AND FAN MOTOR.
1) Press the FRESH/RECIRC switch
(FRESH/RECIRC switch LED illuminates at
this time.).
2) Refer to OPERATING MODE TABLE to
check the operation of each actuator, compres-
sor and fan motor. ING MODE TABLE, OPERATION, Diagnostic
Chart for Self-Diagnosis.>
Also check for each step is possible respec-
tively every time AUTO switch pressed. (At this
time, the AUTO switch LED illuminates.)Does each actuator, compres-
sor and fan motor operate
according to operating mode
table?Press the OFF
switch or turn the
ignition switch to
OFF and finish the
self-diagnosis
mode.Refer to each
diagnostics chart
for actuator, com-
pressor and fan
motor, and repair
the malfunctioning
par t as necessary.
Diagnostics for A/
C System Mal-
function.> AC-21, Diagnostic
Procedure for
Actuators.>
5 CHECK POOR CONTACT.
Check the auto A/C control module connector
for poor contact.Is there a poor contact in con-
nector?Replace the auto
A/C control mod-
ule.Repair the con-
nector.

AC-13
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
Step Check Yes No
1 CHECK FUSE.
1) Turn the ignition switch to OFF.
2) Remove the fuse No. 2 from main fuse box.
3) Check the condition of fuse.Is the fuse blown-out? Replace the fuse. Go to step 2.
2 CHECK FUSE.
1) Turn the ignition switch to OFF.
2) Remove the fuse No. 17 from fuse & relay
box.
3) Check the condition of fuse.Is the fuse blown-out? Replace the fuse. Go to step 3.
3 CHECK AUTO A/C CONTROL MODULE
POWER CIRCUIT.
1) Pull out the auto A/C control module con-
nector.
2) Measure the voltage between auto A/C
control module connector terminal and chassis
ground after turning the ignition switch to OFF
position.
Connector & terminal
(i49) No. 4 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 4.Check open or
short circuit in har-
ness between auto
A/C control mod-
ule and fuse.
4 CHECK AUTO A/C CONTROL MODULE
POWER CIRCUIT.
Measure the voltage between auto A/C control
module connector terminal and chassis ground
after turning the ignition switch to ON position.
Connector & terminal
(i49) No. 5 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 5.Check open or
short circuit in har-
ness between auto
A/C control mod-
ule and fuse.
5 CHECK AUTO A/C CONTROL MODULE
GROUND CIRCUIT.
Measure the resistance in harness between
auto A/C control module and chassis ground.
Connector & terminal
(i49) No. 11 — Chassis ground:Is the resistance less than 1
Ω?Go to step 6.Repair the har-
ness for ground
line.
6 CHECK POOR CONTACT.
Check poor contact in auto A/C control module
connector.Is there poor contact in con-
nector?Repair the con-
nector.Replace the auto
A/C control mod-
ule.

AC-15
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
Step Check Yes No
1 CHECK FUSE.
1) Remove the fuse No. 1, 2 and 17 from fuse
& relay box.
2) Check the condition of fuse.Is any fuse blown-out? Replace the fuse. Go to step 2.
2 CHECK POWER SUPPLY FOR BLOWER
MOTOR.
1) Turn the ignition switch to ON.
2) Turn the fan speed control dial clockwise.
3) Measure the voltage between blower motor
and chassis ground.
Connector & terminal
(B87) No. 1 (+) — Chassis ground (
−):Is the voltage more than 8 V (at
normal temperature)?Go to step 3.Repair the open
circuit of blower
motor power sup-
ply line harness.
3 CHECK BLOWER MOTOR RELAY.
1) Turn the ignition switch to OFF.
2) Remove the blower motor relay.
3) Connect the battery positive (+) terminal to
terminal No. 1 of blower motor relay, and nega-
tive (−) terminal to terminal No. 3.
4) Measure the resistance between terminals
No. 2 and 4.
Te r m i n a l s
No. 2 — No. 4:Is the resistance less than 1
Ω?Go to step 4.Replace the
blower motor relay.
4 CHECK BLOWER MOTOR.
1) Disconnect the connector from blower
motor.
2) Connect the battery positive (+) terminal to
terminal No. 1 of blower motor connector, and
negative (−) terminal to terminal No. 2 and No.
5.
3) Make sure the blower motor runs.Does the blower motor run? Go to step 5.Replace the
blower motor.
5 CHECK POOR CONTACT.
Check poor contact in auto A/C control module
connector.Is there poor contact in con-
nector?Repair the con-
nector.Replace the auto
A/C control mod-
ule.

AC-18
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
Step Check Yes No
1 CHECK FUSE.
1) Turn the ignition switch to OFF.
2) Remove the main fan fuse and sub fan fuse
in main fuse box.
3) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Go to step 2.
2 CHECK THE POWER SUPPLY TO PRES-
SURE SWITCH.
1) Disconnect the connector from pressure
switch.
2) Turn the ignition switch to ON.
3) Measure the voltage between harness con-
nector and chassis ground.
Connector & terminal
(F79) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 3.Repair the har-
ness for pressure
switch power sup-
ply circuit.
3 CHECK THE HARNESS BETWEEN PRES-
SURE SWITCH AND A/C RELAY HARNESS.
1) Turn the ignition switch to OFF.
2) Remove the A/C relay in the main fuse box.
3) Measure the resistance between A/C relay
and pressure switch connector.
Connector & terminal
(F27) No. 17 — (F79) No. 2:Is the resistance less than 1
Ω?Go to step 4.Repair the har-
ness between A/C
relay and pres-
sure switch.
4 CHECK THE PRESSURE SWITCH.
Measure the resistance between pressure
switch terminals.
Te r m i n a l s
No. 1 — No. 2:Is the resistance less than 1
Ω?Go to step 5.Replace the pres-
sure switch.
5 CHECK THE A/C CUT SIGNAL CIRCUIT.
1) Disconnect the connector from auto A/C
control module.
2) Measure the resistance between auto A/C
control module and pressure switch connector.
Connector & terminal
(i48) No. 10 — (F79) No. 2:Is the resistance less than 1
Ω?Go to step 6.Repair the har-
ness between auto
A/C control mod-
ule and pressure
switch.
6 CHECK THE A/C ON SIGNAL CIRCUIT.
1) Disconnect the connector from ECM.
2) Measure the resistance between ECM and
auto A/C control module connector.
Connector & terminal
Turbo model
(B137) No. 17 — (i49) No. 17:
Non-turbo model
(B136) No. 11 — (i49) No. 17:Is the resistance less than 1
Ω?Go to step 7.Repair the har-
ness between auto
A/C control mod-
ule and ECM.
7 CHECK A/C RELAY.
1) Remove the A/C relay in main fuse box.
2) Check the A/C relay. INSPECTION, Relay and Fuse.>Is the operation of the relay
OK?Go to step 8.Replace the A/C
relay.
8 CHECK POWER SUPPLY TO MAGNET
CLUTCH OF A/C COMPRESSOR.
1) Turn the ignition switch to OFF, and then
connect the A/C relay connector and all
removed connectors.
2) Start the engine, and turn A/C switch to
ON.
3) Set the temperature control dial to maxi-
mum cold position.
4) Measure the voltage between magnet
clutch harness connector and chassis ground.
Connector & terminal
(F24) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10.5 V
(at normal temperature)?Go to step 9.Repair the har-
ness for power
supply line of A/C
compressor.

AC-19
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
9 CHECK OPERATION OF MAIN FAN MOTOR.
1) Start the engine and turn the A/C switch to
ON.
2) Check the operation of main fan motor.Does the main fan motor oper-
ate normally?Go to step 14.Go to step 10.
10 CHECK POWER SUPPLY TO MAIN FAN MO-
TOR.
CAUTION:
Be careful not to overheat the engine during
repair.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from main fan
motor.
3) Start the engine, and warm it up until
engine coolant temperature increases over
100°C (212°F).
4) Stop the engine and turn ignition switch to
ON.
5) Measure the voltage between main fan
motor harness connector and chassis ground.
Connector & terminal
Except turbo AT model:
(F17) No. 2 (+) — Chassis ground (
−):
Turbo AT model:
(F17) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 11.Repair the har-
ness for main fan
motor power sup-
ply circuit.
11 CHECK GROUND CIRCUIT OF MAIN FAN
MOTOR.
Measure the resistance between main fan
motor harness connector and chassis ground.
Connector & terminal
Except turbo AT model:
(F17) No. 1 — Chassis ground:
Turbo AT model:
(F17) No. 2 — Chassis ground:Is the resistance less than 1
Ω?Go to step 12.Repair the har-
ness for main fan
motor ground cir-
cuit.
12 CHECK MAIN FAN MOTOR.
Connect the battery positive (+) terminal to ter-
minal No. 2, and ground (−) terminal to termi-
nal No. 1 of main fan motor connector to make
sure that main fan motor rotate.Does the main fan rotate? Go to step 13.Replace the main
fan motor.
13 CHECK POOR CONTACT IN MAIN FAN MO-
TOR CONNECTOR.
Check poor contact in main fan motor harness
connector.Is there poor contact in con-
nector?Go to step 14.Repair the poor
contact in main fan
motor connector.
14 CHECK OPERATION OF SUB FAN MOTOR.
1) Start the engine and turn the A/C switch to
ON.
2) Check the operation of sub fan motor.Does the sub fan motor oper-
ate normally?Go to step 19.Go to step 15. Step Check Yes No

AC-20
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
15 CHECK POWER SUPPLY TO SUB FAN MO-
TOR.
CAUTION:
Be careful not to overheat the engine during
repair.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from sub fan
motor.
3) Start the engine, and warm it up until
engine coolant temperature increases over
100°C (212°F).
4) Stop the engine and turn ignition switch to
ON.
5) Measure the voltage between sub fan
motor harness connector and chassis ground.
Connector & terminal
Except turbo AT model:
(F16) No. 2 (+) — Chassis ground (
−):
Turbo AT model:
(F16) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 16.Repair the har-
ness for sub fan
motor power sup-
ply circuit.
16 CHECK GROUND CIRCUIT OF SUB FAN
MOTOR.
Measure the resistance between sub fan motor
harness connector and chassis ground.
Connector & terminal
Except turbo AT model:
(F16) No. 1 — Chassis ground:
Turbo AT model:
(F16) No. 2 — Chassis ground:Is the resistance less than 1
Ω?Go to step 17.Repair the har-
ness for sub fan
motor ground cir-
cuit.
17 CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to ter-
minal No. 2, and ground (−) terminal to termi-
nal No. 1 of sub fan motor connector to make
sure that sub fan motor rotate.Does the sub fan motor rotate? Go to step 18.Replace the sub
fan motor.
18 CHECK POOR CONTACT IN SUB FAN MO-
TOR CONNECTOR.
Check poor contact in sub fan motor connec-
tor.Is there poor contact in con-
nector?Go to step 19.Repair the poor
contact in sub fan
motor connector.
19 CHECK POOR CONTACT IN AUTO A/C
CONTROL MODULE CONNECTOR.
Check poor contact in auto A/C control module
connector.Is there poor contact in con-
nector?Replace the auto
A/C control mod-
ule.Repair the con-
nector. Step Check Yes No

AC-22
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Procedure for Actuators
Step Check Yes No
1 CHECK POWER SUPPLY FOR INTAKE
DOOR ACTUATOR.
1) Turn the ignition switch to OFF.
2) Disconnect the intake door actuator con-
nector.
3) Turn the ignition switch to ON.
4) Measure the voltage between intake door
actuator connector and chassis ground.
Connector & terminal
(B91) No. 4 (+) — Chassis ground (
−):Is the voltage 7 V (at normal
temperature)?Go to step 2.Check open or
short circuit in har-
ness between
intake door actua-
tor and fuse.
2 CHECK HARNESS BETWEEN AUTO A/C
CONTROL MODULE AND INTAKE DOOR
ACTUATOR.
1) Turn the ignition switch to OFF.
2) Disconnect the auto A/C control module
connector.
3) Measure the resistance between intake
door actuator connector and auto A/C control
module connector.
Connector & terminal
LHD model:
(i49) No. 18 — (B91) No. 2:
(i49) No. 19 — (B91) No. 3:
(i49) No. 20 — (B91) No. 1:
RHD model:
(i49) No. 18 — (B91) No. 1:
(i49) No. 19 — (B91) No. 3:
(i49) No. 20 — (B91) No. 2:Is the resistance less than 1
Ω?Go to step 3.Repair the har-
ness between auto
A/C control mod-
ule and intake
door actuator.
3 CHECK OPERATION OF INTAKE DOOR AC-
TUATOR.
1) Connect the intake door actuator connec-
tor.
2) Ground the auto A/C control module con-
nector with a suitable wire.
3) Turn the ignition switch to ON, and check
the operation of intake door actuator.
Connector & terminal
(i49) No. 20 — Chassis ground:Does the actuator move to
FRESH side?Go to step 4.Replace the intake
door actuator.
4 CHECK OPERATION OF INTAKE DOOR AC-
TUATOR.
1) Turn the ignition switch to OFF.
2) Ground the auto A/C control module con-
nector with a suitable wire.
3) Turn the ignition switch to ON, and check
the operation of intake door actuator.
Connector & terminal:
(i49) No. 18 — Chassis ground:Does the actuator move to
RECIRC side?Replace the auto
A/C control mod-
ule.Replace the intake
door actuator.

AC-24
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Procedure for Actuators
Step Check Yes No
1 CHECK POWER SUPPLY FOR AUTO A/C
CONTROL MODULE SIDE.
1) Turn the ignition switch to ON.
2) Turn the mode control dial to VENT posi-
tion.
3) Press the defroster switch and measure the
voltage between auto A/C control module and
chassis ground when VENT is changed to DEF
position.
Connector & terminal
(i49) No. 9 (+) — Chassis ground (
−):Is the voltage more than 12 V? Go to step 2.Replace the auto
A/C control mod-
ule.
2 CHECK POWER SUPPLY FOR ACTUATOR
SIDE.
1) Turn the mode control dial to VENT posi-
tion.
2) Press the defroster switch and measure the
voltage between mode door actuator harness
connector and chassis ground when VENT is
changed to DEF position.
Connector & terminal
(B77) No. 1 (+) — Chassis ground (
−):Is the voltage more than 7 V (at
normal temperature)?Go to step 3.Repair the har-
ness between auto
A/C control mod-
ule and mode door
actuator.
3 CHECK POWER SUPPLY FOR AUTO A/C
CONTROL MODULE SIDE.
1) Press the defroster switch.
2) Turn the mode control dial to VENT position
and measure the voltage between auto A/C
control module and chassis ground when DEF
is changed to VENT position.
Connector & terminal
(i49) No. 8 (+) — Chassis ground (
−):Is the voltage more than 12 V? Go to step 4.Replace the auto
A/C control mod-
ule.
4 CHECK POWER SUPPLY FOR ACTUATOR
SIDE.
1) Press the defroster switch.
2) Turn the mode control dial to VENT position
and measure the voltage between mode door
actuator harness connector and chassis
ground when DEF is changed to VENT posi-
tion.
Connector & terminal
(B77) No. 2 (+) — Chassis ground (
−):Is the voltage more than 7 V (at
normal temperature)?Go to step 5.Repair the har-
ness between auto
A/C control mod-
ule and mode door
actuator.
5 CHECK ACTUATOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from mode door
actuator.
3) Connect the battery positive (+) terminal to
terminal No. 1 and ground (−) terminal to termi-
nal No. 2 of mode door actuator to make sure
that actuator operates.
4) Connect the battery positive (+) terminal to
terminal No. 2 and ground (−) terminal to termi-
nal No. 1 of mode door actuator to make sure
that actuator operates.Does the motor operate nor-
mally?Go to step 6.Replace the mode
door actuator.