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

CRUISE CONTROL SYSTEM
CC
Page
1. General Description ....................................................................................2
2. Actuator .......................................................................................................5
3. Cruise Control Module ................................................................................7
4. Cruise Control Main Switch .........................................................................8
5. Cruise Control Command Switch ................................................................9
6. Stop and Brake Switch ..............................................................................10
7. Clutch Switch ............................................................................................11
8. Inhibitor Switch (AT model) .......................................................................12
9. Neutral Position Switch (MT model) ..........................................................13

CC-2
CRUISE CONTROL SYSTEM
General Description
1. General Description
A: COMPONENT
1. EXCEPT 2.5 L TURBO MODEL
NOTE:
Electrical component location are for LHD vehicles. Cruise control actuator and cruise control module loca-
tion for RHD vehicles are symmetrically opposite.
(1)(2)
(3)
(4)
(5)
(6)
(7)
CC-00001
(1) Actuator (4) Cruise control main switch (7) Cruise control module
(2) Inhibitor switch (AT model) (5) Clutch switch (MT model)
(3) Cruise control command switch (6) Stop and brake switch

CC-3
CRUISE CONTROL SYSTEM
General Description
2. 2.5 L TURBO MODEL
(1)
(2)
(3)
(4) (6)(7)
CC-00262 (5)
(1) Inhibitor switch (AT model) (4) Clutch switch (MT model) (7) Neutral position switch (MT
model)
(2) Cruise control command switch (5) Stop and brake switch
(3) Cruise control main switch (6) Engine control module

CC-4
CRUISE CONTROL SYSTEM
General Description
B: CAUTION
 Before disassembling or reassembling parts, al-
ways disconnect the battery ground cable. When re-
pairing the radio, control module and other parts with
memory functions, make note of the memory before
disconnecting the battery ground cable. All memory
will be erased.
 Reassemble parts in the reverse order of disas-
sembly unless otherwise indicated.
 Adjust parts to specifications specified in this man-
ual.
 Connect the connectors and hoses securely dur-
ing reassembly.
 After reassembly, ensure functional parts operate
properly.
C: PREPARATION TOOL
TOOL NAME REMARKS
Circuit Tester Used for measuring resis-
tance and voltage.

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)

CC-6
CRUISE CONTROL SYSTEM
Actuator
C: INSPECTION
Measure the cruise control actuator resistance.
If NG, replace the cruise control actuator.
Terminal No. Standard
4 and 1 Approx. 5 Ω
4 and 2 Approx. 5 Ω
4 and 5 Approx. 5 Ω
3 and 6 Approx. 39 Ω
CC-00012
1 3
4 5 62

CC-7
CRUISE CONTROL SYSTEM
Cruise Control Module
3. Cruise Control Module
A: NOTE
Engine Control Module (ECM) controls cruise con-
trol system (Turbo model).
B: REMOVAL
1. NON-TURBO MODEL
1) Disconnect the ground cable from battery.
2) Remove the glove box. AL, Glove Box.>
3) Disconnect the connector from cruise control
module.
4) Remove the bolt, then detach the cruise control
module (A).
2. TURBO MODEL
Control Module (ECM).>
C: INSTALLATION
1. NON-TURBO MODEL
Install in the reverse order of removal.
NOTE:
Attach the part number label, facing the rear side of
the vehicle.
2. TURBO MODEL
gine Control Module (ECM).>
CC-00013
(A)

CC-8
CRUISE CONTROL SYSTEM
Cruise Control Main Switch
4. Cruise Control Main Switch
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the screws and clip from instrument
panel lower cover.
3) Remove the instrument panel lower cover.
4) Disconnect the connector from cruise control
main switch.
5) Remove the main switch by pushing it outward.
 For Europe model
 For Australia model
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure the cruise control main switch resistance.
If NG, replace the cruise control main switch.
CC-00014
CC-00015
CC-00071
CC-00072
Switch position Terminal No. Standard
OFF (released)LHD, RHD (For
Europe) model : 1
and 2More than 1 MΩ
ON (depressed)RHD (Except for
Europe) model : 3
and 5Less than 1 Ω
CC-00073
1 2
64
53