wheel SUBARU FORESTER 2004 Service User Guide

SB-16
SEAT BELT SYSTEM
Disposal of Pretensioner
2. DEPLOYING OF RETRACTOR PRETEN-
SIONER AFTER REMOVAL FROM VEHICLE
1) Fold backrest all the way forward, then move
front seat all the way forward.
2) Turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait for more than
20 seconds before starting work.
3) Remove the front outer belt. MOVAL, Front Seat Belt.>
4) Cut off the seat belt as close to retractor as pos-
sible.
5) Short the terminal to alligator clip furnished as a
deployment tool.
6) Connect the deployment tool (A) and deploy-
ment adapter D (B).
CAUTION:
The deployment tool terminals should be kept
shorted until just before deployment of the pre-
tensioner.
7) Connect the deployment adapter D connector
and pretensioner yellow connector.8) Install the pretensioner on a wheel with tire.
Then, bundle three wire automotive harness [each
with a sectional area of 1.25 mm
2 (0.00194 sq in) or
more], and bind them twofold around the preten-
sioner bracket and wheel.
9) Put three tires without a wheel on the tire in-
stalled with pretensioner. Put on an additional tire
with a wheel on top, and then fasten them tight with
a rope.
10) Move the battery at least 5 m (16 ft) from the
vehicle, and secure the nearby area. Connect the
deployment tool alligator clip to the battery negative
(−) terminal.
(A) Deployment tool: (Tool No. 98299PA030)
(B) Deployment adapter D: (Tool No. 98299SA010)
SB-00130
SB-00021
(A)
(B)
(1) 5 m (16 ft) or more
SB-00024
SB-00025
SB-00065
(1)

SB-17
SEAT BELT SYSTEM
Disposal of Pretensioner
11) Connect the other cable of deployment tool to
the battery positive (+) terminal. Then deploy the
pretensioner.
CAUTION:
 After deployment, pretensioner is especially
hot. Leave it unattended for 40 minutes or long-
er.
 Do not let water get on the deployed preten-
sioner.
12) Wrap the deployed pretensioner in an airtight
vinyl bag, and discard it.
3. DEPLOYING LAP PRETENSIONER AF-
TER REMOVAL FROM VEHICLE
1) Fold backrest all the way forward, then move
front seat all the way forward.
2) Turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait for more than
20 seconds before starting work.
3) Remove the fornt outer belt. MOVAL, Front Seat Belt.>
4) Cut off the seat belt as close to lap seat belt pre-
tensioner as possible.5) Short the terminal to alligator clip furnished as a
deployment tool (A).
6) Connect the deployment tool and deployment
adapter F (B).
CAUTION:
The deployment tool terminals should be kept
shorted until just before deployment of the pre-
tensioner.
7) Connect the deployment adapter F connector to
pretensioner yellow connector.
8) Install the pretensioner on a wheel with tire.
Then, bundle three wire automotive harness [each
with a sectional area of 1.25 mm
2 (0.00194 sq in) or
more], and bind them twofold around the preten-
sioner bracket and wheel.
9) Put three tires without a wheel on the tire in-
stalled with pretensioner. Put on an additional tire
with a wheel on top, and then fasten them tight with
a rope.
SB-00018
SB-00131
SB-00027
(A) Deployment tool: (Tool No. 98299PA030)
(B) Deployment adapter F: (Tool No. 98299SA050)
SB-00021
(A)
(B)
SB-00028
SB-00025

COM-5
COMMUNICATION SYSTEM
Horn Switch
4. Horn Switch
A: REMOVAL
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the driver
airbag module. al Description.>
1) Disconnect the ground cable from battery.
2) Remove the driver’s airbag module. 14, Driver’s Airbag Module.>
3) Remove the horn switch from the steering wheel
as shown in the figure.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure the horn switch resistance.
Switch position Terminal No. Resistance
When horn switch
is pushed.
1 and body
groundLess than 1Ω
When horn switch
is not pushed.More than 1MΩ
COM00004
2
5
4
COM00005
1

IDI-5
INSTRUMENTATION/DRIVER INFO
Combination Meter System
2. CHECK POWER SUPPLY AND GROUND CIRCUIT
3. CHECK VEHICLE SPEED SENSOR
Step Check Yes No
1 CHECK POWER SUPPLY FOR COMBINA-
TION METER.
1) Remove the combination meter. IDI-10, REMOVAL, Combination Meter
Assembly.>
2) Disconnect the combination meter harness
connector.
3) Turn the ignition switch to ON.
4) Measure the voltage between combination
meter connector and chassis ground.
Connector & terminal
(i10) No. 9 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 2.Check the harness
for open or short
between ignition
switch and combi-
nation meter.
2 CHECK POWER SUPPLY FOR COMBINA-
TION METER.
Measure the voltage between combination
meter connector and chassis ground.
Connector & terminal
(i10) No. 8 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 3.Check the harness
for open or short
between fuse and
combination
meter.
3 CHECK GROUND CIRCUIT OF COMBINA-
TION METER.
1) Turn the ignition switch to OFF.
2) Measure the resistance of harness
between combination meter connector and
chassis ground.
Connector & terminal
(i10) No. 10 — Chassis ground:Is the resistance less than 10
Ω?Replace the com-
bination meter
printed circuit.Repair the wiring
harness.
Step Check Yes No
1 CHECK VEHICLE SPEED SENSOR.
1) Lift-up the vehicle and support it with rigid
racks.
2) Remove the combination meter with har-
ness connector.
3) Drive the vehicle at a speed greater than 20
km/h (12 MPH).
Warning:
Be careful not to get caught in the running
wheels.
4) Measure the voltage between combination
meter connector and chassis ground.
Connector & terminal
(i10) No. 12 (+) — Chassis ground (
−):Is the voltage 1 V ← → 5 V? Check the speed-
ometer. IDI-13, INSPEC-
TION, Speedome-
ter.>Go to step 2.
2 CHECK VEHICLE SPEED SENSOR POWER
SUPPLY.
1) Turn the ignition switch to OFF.
2) Disconnect the vehicle speed sensor har-
ness connector.
3) Turn the ignition switch to ON.
4) Measure the voltage between vehicle
speed sensor connector and engine ground.
Connector & terminal
(B17) No. 3 (+) — Engine ground (
−):Is the voltage more than 10 V? Go to step 3.Check the harness
for open or short
between ignition
switch and vehicle
speed sensor.

IDI-6
INSTRUMENTATION/DRIVER INFO
Combination Meter System
4. CHECK TRANSMISSION CONTROL MODULE (TCM)
3 CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND ENGINE GROUND.
1) Turn the ignition switch to OFF.
2) Measure the resistance between vehicle
speed sensor connector and engine ground.
Connector & terminal
(B17) No. 2 — Engine ground:Is the resistance less than 10
Ω?Go to step 4.Repair the wiring
harness.
4 CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND COMBINATION
METER.
1) Disconnect the connector from combination
meter.
2) Measure the resistance between vehicle
speed sensor harness connector and combi-
nation meter harness connector.
Connector & terminal
(B17) No. 1 — (i10) No. 12:Is the resistance less than 10
Ω?Replace the vehi-
cle speed sensor.Repair the wiring
harness.
Step Check Yes No
1 CHECK TCM SIGNAL.
1) Lift-up the vehicle and support it with rigid
racks.
2) Drive the vehicle faster than 10 km/h (6
MPH).
Warning:
Be careful not to get caught in the running
wheels.
3) Measure the voltage between TCM con-
nector and chassis ground.
Connector & terminal
(B56) No. 17 (+) — Chassis ground (
−):Is the voltage 1 V ← → 5 V? Go to step 2.Check TCM. to 4AT(H4SO)-2,
Basic Diagnostic
Procedure.>
2 CHECK HARNESS BETWEEN TCM AND
COMBINATION METER.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from TCM and
combination meter.
3) Measure the resistance between TCM har-
ness connector and combination meter har-
ness connector.
Connector & terminal
(B56) No. 17 — (i10) No. 12:Is the resistance less than 10
Ω?Check the speedo
meter. 13, INSPECTION,
Speedometer.>Repair the wiring
harness. Step Check Yes No

EI-28
EXTERIOR/INTERIOR TRIM
Front Bumper
9 WeldingUsing a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam-
aged area.
(1) Melt hatched area
(2) Welding rod
(3) Section
N
OTE:
 Melt the sections indicated by hatched area.
 Do not melt the welding rod until it flows out, in order to provide strength.
 Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
 Leave the welded spot unattended until it cools completely.
10 Sanding (II)Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife,
operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will
cause the PP substrate to melt from the heat.
Sand the welded spot smooth with #240 sand paper.
11 MaskingMask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
12Cleaning/
degreasingCompletely clean the entire coated area, using solvent similar to that used in Process No. 4.
13 Primer coatingApply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if nec-
essary.
Recommended primer: Mp/ 364 PP Primer
N
OTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa
(2.5 to 3.5 kg/cm
2, 36 to 50 psi) with a spray gun.
14 Leave unattended.Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is half-dry.
N
OTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended with alcohol.
(Do not use thinner since the coated area tends to melt.)
15Primer surfacer
coatingApply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 min-
utes.
Recommended surfacer:
 UPS 300 Flex Primer
 No. 303 UPS 300 Exclusive hardener
 NPS 725 Exclusive Reducer (thinner)
 Mixing ratio: 2: 1 (UPS 300: No. 303)
 Viscosity: 12 — 14 sec/20°C (68°F)
 Coated film thickness: 40 — 50µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water.
18Cleaning/
degreasingSame as Process No. 12. Pro-
cess
No.Process name Job contents
EI-00237 (1)(2)(2)
(3)
EI-00042

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. General Description.>
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

CC(H4SO)-8
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Cruise Control Module I/O Signal
B: WIRING DIAGRAM

Brake switch/Clutch switch
(MT model)16 Leave clutch pedal released (MT model), while cruise control main switch is
turned ON.
Then check that;
 Battery voltage is present when brake pedal is released.
 “0” volt is present when brake pedal is depressed.
Additionally only in MT model, keep the cruise control main switch to ON and
leave brake pedal released.
Then check that;
 Battery voltage is present when clutch pedal is released.
 “0” volt is present when clutch pedal is depressed.
Data link connector 17 —
Data link connector 18 —
Vehicle speed sensor (MT
model)
TCM (AT model)19 Lift-up the vehicle until all four wheels are raised off ground, and then rotate any
wheel manually.
Approx. “5” and “0” volt pulse signals are alternately input to cruise control mod-
ule.
Stop light switch 20 Turn ignition switch to OFF.
Then check that;
 Battery voltage is present when brake pedal is depressed.
 “0” volt is present when brake pedal is released.
NOTE:
Voltage at terminals 5, 7, 13 and 14 cannot be checked unless vehicle is driving by cruise control operation.Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)

CC(H4SO)-31
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK TRANSMISSION TYPE.Is the target MT model? Go to step 2.Go to step 6.
2 CHECK HARNESS BETWEEN BATTERY
AND VEHICLE SPEED SENSOR.
1) Turn the ignition switch to OFF.
2) Disconnect the harness connector from
vehicle speed sensor.
3) Turn the ignition switch to ON.
4) Measure the voltage between vehicle
speed sensor harness connector terminal and
chassis ground.
Connector & terminal
(B17) No. 3 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 3.Check the harness
for open or short
between fuse relay
and vehicle speed
sensor.
3 CHECK HARNESS BETWEEN CRUISE CON-
TROL MODULE AND VEHICLE SPEED SEN-
SOR.
1) Turn the ignition switch to OFF.
2) Disconnect the harness connector from
cruise control module.
3) Measure the resistance between vehicle
speed sensor harness connector terminal and
cruise control module harness connector ter-
minal.
Connector & terminal
(B17) No. 1 — (B94) No. 19:Is the resistance less than 10
Ω?Go to step 4.Repair the har-
ness.
4 CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND ENGINE GROUND.
1) Turn the ignition switch to OFF.
2) Measure the resistance between vehicle
speed sensor harness connector terminal and
engine ground.
Connector & terminal
(B17) No. 2 — Engine ground:Is the resistance less than 10
Ω?Go to step 5.Repair the har-
ness.
5 CHECK VEHICLE SPEED SENSOR.
1) Connect the harness connector to vehicle
speed sensor.
2) Lift-up the vehicle and support with rigid
racks.
3) Drive the vehicle at speed greater than 20
km/h (12 MPH).
Warning:
Be careful not to be caught up by the run-
ning wheels.
4) Measure the voltage between cruise control
module harness connector terminal and chas-
sis ground.
Connector & terminal
(B94) No. 19 (+) — Chassis ground (
−):Is the voltage less than 0 V ←
→ more than 5 V?Replace the cruise
control module.
Cruise Control
Module.>Replace the vehi-
cle speed sensor.
6 CHECK HARNESS BETWEEN CRUISE CON-
TROL MODULE AND TCM.
1) Turn the ignition switch to OFF.
2) Disconnect the harness connector from
TCM and cruise control module.
3) Measure the resistance between cruise
control module harness connector terminal
and TCM harness connector terminal.
Connector & terminal
(B94) No. 19 — (B56) No. 17:Is the resistance less than 10
Ω?Go to step 7.Repair the har-
ness.

CC(H4SO)-32
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
7 CHECK TCM.
1) Connect the harness connector to TCM.
2) Lift-up the vehicle and support with rigid
racks.
3) Drive the vehicle faster than 10 km/h (6
MPH).
Warning:
Be careful not to be caught by the running
wheels.
4) Measure the voltage between TCM har-
ness connector terminal and chassis ground.
Connector & terminal
(B56) No. 17 (+) — Chassis ground (
−):Is the voltage less than 0 V ←
→ more than 5 V?Replace the cruise
control module.
Cruise Control
Module.>Replace the TCM.
Transmission Con-
trol Module
(TCM).> Step Check Yes No