fuse SUBARU FORESTER 2004 Service Workshop Manual

CC(H4DOTC 2.5)-25
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK IGNITION SWITCH CIRCUIT.
1) Turn the ignition switch to OFF.
2) Disconnect the ECM harness connector.
3) Turn the ignition switch to ON.
4) Measure the voltage between harness con-
nector terminal and chassis ground.
Connector & terminal
(B137) No. 14 (+) — Chassis ground (
−): Is the voltage more than 10 V? Check the poor
contact of ECM
connector. Check the fuse
No. 11 (fuse &
relay box).
 Check the har-
ness for open or
short between
ignition switch and
ECM.

CC(H4DOTC 2.5)-27
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 and
vehicle speed sen-
sor.
3 CHECK HARNESS BETWEEN ECM AND VE-
HICLE SPEED SENSOR.
1) Turn the ignition switch to OFF.
2) Disconnect the harness connector from
ECM.
3) Measure the resistance between vehicle
speed sensor harness connector terminal and
ECM harness connector terminal.
Connector & terminal
(B17) No. 1 — (B135) No. 26: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 ECM har-
ness connector terminal and chassis ground.
Connector & terminal
(B135) No. 26 (+) — Chassis ground (
−):Is the voltage 1 V ← → 5 V? Check the poor
contact of ECM
connector.Replace the vehi-
cle speed sensor.
6 CHECK HARNESS BETWEEN ECM AND
TCM.
1) Turn the ignition switch to OFF.
2) Disconnect the harness connector from
ECM and TCM.
3) Measure the resistance between ECM har-
ness connector terminal and TCM harness
connector terminal.
Connector & terminal
(B135) No. 26 — (B56) No. 1:Is the resistance less than 10
Ω?Go to step 7.Repair the har-
ness.

IM-11
IMMOBILIZER (DIAGNOSTIC)
Diagnostics Chart for Immobilizer Warning Light
Step Check Yes No
1 CHECK IMMOBILIZER WARNING LIGHT.
1) Turn the ignition switch to OFF.
2) Disconnect the harness connector from
IMM ECM.
3) Connect a resistor (750 Ω) between IMM
ECM harness connector terminal No. 9 and
chassis ground.Does the immobilizer warning
light illuminate?Go to step 2.Go to step 5.
2 CHECK IMM ECM GROUND CIRCUIT.
Measure the resistance between IMM ECM
harness connector terminal and chassis
ground.
Connector & terminal
(B141) No. 2, No. 3 — Chassis ground:Is the resistance less than 10
Ω?Go to step 3.Repair the open
circuit of IMMECM
ground circuit.
3 CHECK IMM ECM IGNITION CIRCUIT.
1) Turn the ignition switch to ON. (engine
OFF.)
2) Measure the voltage between IMM ECM
harness connector terminal and chassis
ground.
Connector & terminal
(B141) No. 12 (+) — Chassis ground(
−):Is the voltage more than 10 V? Go to step 4.Check the harness
for open or short
between IMM
ECM and ignition
switch.
4 CHECK IMM ECM POWER SUPPLY CIR-
CUIT.
1) Turn the ignition switch to OFF.
2) Measure the voltage between IMM ECM
harness connector terminal and chassis
ground.
Connector & terminal
(B141) No. 10, No. 11 (+) — Chassis
ground(
−):Is the voltage more than 10 V? Replace the IMM
ECM 37, Immobilizer
Control Module.>
and then replace
all ignition keys
(including the tran-
sponder). Then
perform teaching
operation. Refer to
teaching opera-
tion manual (Pub.
No. S0820GZ).Check the harness
for open or short
between IMM
ECM and fuse.
5 CHECK COMBINATION METER CIRCUIT.
1) Remove the combination meter. IDI-10, Combination Meter Assembly.>
2) Measure the voltage between combination
meter harness connector terminal and chassis
ground.
Connector & terminal
(i10) No. 8 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 6.Check the harness
for open or short
between combina-
tion meter and
fuse.
6 CHECK COMBINATION METER CIRCUIT.
Measure the resistance between IMM ECM
harness connector terminal and combination
meter harness connector terminal.
Connector & terminal
LHD model
(B141) No. 9 — (i12) No. 4:
RHD model
(B141) No. 9 — (i11) No. 5:Is the resistance less than 10
Ω?Faulty LED.
Replace the com-
bination meter
printed circuit.
DISASSEMBLY,
Combination
Meter Assembly.>Repair the har-
ness or connector.

IM-13
IMMOBILIZER (DIAGNOSTIC)
Diagnostics Chart for Immobilizer Warning Light
Step Check Yes No
1 CHECK POWER SUPPLY CIRCUIT.
1) Disconnect the harness connector from key
warning switch.
2) Measure the voltage between key warning
switch harness connector terminal and chassis
ground.
Connector & terminal
(B74) No. 2 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 2.Check the harness
for open or short
between key warn-
ing switch and
fuse.
2 CHECK KEY WARNING SWITCH.
1) Insert the ignition key to the ignition switch.
(OFF or ACC position)
2) Measure the resistance between key warn-
ing switch connector terminals.
Te r m i n a l
No. 1 — No. 2:Is the resistance less than 1
Ω?Go to step 3.Replace the key
warning switch.
3 CHECK KEY WARNING SWITCH.
1) Remove the ignition key from the ignition
switch.
2) Measure the resistance between key warn-
ing switch connector terminals.
Te r m i n a l
No. 1 — No. 2:Is the resistance more than
1 MΩ?Go to step 4.Replace the key
warning switch.
4 CHECK HARNESS BETWEEN KEY WARN-
ING SWITCH AND IMM ECM.
1) Disconnect the harness connector from key
warning switch.
2) Disconnect the harness connector from
IMM ECM.
3) Measure the resistance between key warn-
ing switch harness connector terminal and
IMM ECM harness connector terminal.
Connector & terminal
(B74) No. 1 — (B141) No. 4:Is the resistance less than 10
Ω?Replace the IMM
ECM 37, Immobilizer
Control Module.>
and then replace
all ignition keys
(including the tran-
sponder). Then
perform teaching
operation. Refer to
teaching opera-
tion manual (Pub.
No. S0820GZ).Repair the har-
ness between key
warning switch
and IMM ECM.

IM-17
IMMOBILIZER (DIAGNOSTIC)
Diagnostics Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK POWER SUPPLY CIRCUIT OF IMM
ECM.
1) Turn the ignition switch to OFF.
2) Disconnect the harness connector from
IMM ECM.
3) Measure the voltage between IMM ECM
harness connector terminal and chassis
ground.
Connector & terminal
(B141) No. 10, No. 11 (+) — Chassis
ground(
−):Is the voltage more than 10 V? Go to step 2.Check the harness
for open or short
between IMM
ECM and fuse.
2 CHECK IGNITION SWITCH CIRCUIT.
1) Turn the ignition switch to ON. (engine
OFF.)
2) Measure the voltage between IMM ECM
harness connector terminal and chassis
ground.
Connector & terminal
(B141) No. 12 (+) — Chassis ground(
−):Is the voltage more than 10 V? Go to step 3.Check the harness
for open or short
between IMM
ECM and ignition
switch.
3 CHECK GROUND CIRCUIT OF IMM ECM.
1) Turn the ignition switch to OFF.
2) Measure the resistance between IMM ECM
harness connector terminal and chassis
ground.
Connector & terminal
(B141) No. 2, No. 3 — Chassis ground:Is the resistance less than 10
Ω?Go to step 4.Repair the open
circuit of IMMECM
ground circuit.
4 CHECK HARNESS BETWEEN IMM ECM
AND ECM.
1) Disconnect the harness connector from
ECM and IMM ECM.
2) Measure the resistance between IMM ECM
harness connector terminal and ECM harness
connector terminal.
Connector & terminal
Non-turbo LHD model
(B141) No. 1 — (B137) No. 17:
Non-turbo RHD model
(B141) No. 1 — (B137) No. 18:
Turbo model
(B141) No. 1 — (B137) No. 19:Is the resistance less than 10
Ω?Go to step 5.Repair the open
circuit of harness
between IMM
ECM and ECM.
5 CHECK HARNESS BETWEEN IMM ECM
AND ECM.
Measure the resistance between IMM ECM
harness connector terminal and ECM harness
connector terminal.
Connector & terminal
Non-turbo LHD model
(B141) No. 6 — (B137) No. 18:
Non-turbo model
(B141) No. 6 — (B137) No. 17:
Turbo model
(B141) No. 6 — (B137) No. 27:Is the resistance less than 10
Ω?Go to step 6.Repair the open
circuit of harness
between IMM
ECM and ECM.

PC-2
PRECAUTION
Precaution
1. Precaution
A: PRECAUTION
Please clearly understand and adhere to the follow-
ing general precautions. They must be strictly fol-
lowed to avoid minor or serious injury to the person
doing the work or people in the area.
1. ABS
Handle the ABS as a total system. Do not disas-
semble or attempt to repair individual parts. Doing
so could prevent the ABS system from operating
when needed or cause it to operate incorrectly and
result in injury.
2. BRAKE FLUID
If brake fluid gets in your eyes or on your skin, do
the following:
 Wash out your eyes and seek immediate medical
attention.
 Wash your skin with soap and then rinse thor-
oughly with water.
3. RADIATOR FAN
The radiator fan may rotate without warning, even
when the engine is not on. Do not place your hand,
cloth, tools, or other items near the fan at any time.
4. ROAD TESTS
Always conduct road tests in accordance with traf-
fic rules and regulations to avoid bodily injury and
interrupting traffic.
5. AIRBAG
To prevent bodily injury from unexpected deploy-
ment of airbags and unnecessary maintenance, fol-
low the instructions in this manual when performing
maintenance on airbag components or nearby, and
airbag wiring harnesses or nearby.
To prevent unexpected deployment, perform the
steps below and then wait at least 20 seconds to
discharge electricity before beginning work.
 Step 1: Turn the ignition switch OFF.
 Step 2: Disconnect the ground cable from bat-
tery.
6. AIRBAG DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose airbag modules in the
same way as other refuse. Follow all government
regulations concerning disposal of refuse.
7. AIRBAG MODULE
Adhere to the following when handling and storing
the airbag module to prevent bodily injury from un-
expected deployment:
 Do not hold the harnesses or connectors to carry
module.
 Do not face the bag in the direction that it opens
towards yourself or other people.
 Do not face the bag in the direction that it opens
towards the floor or walls.
8. AIRBAG SPECIAL TOOLS
To prevent unexpected deployment, only use spe-
cial tools.
9. WINDOW
Always wear safety glasses when working around
any glass to prevent glass fragments from damag-
ing your eyes.
10.WINDOW ADHESIVE
Always use the recommended or alternative adhe-
sive when attaching glass to prevent it from coming
loose and falling, resulting in accidents and injury.

PI-3
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
B: PDI PROCEDURE
Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt
Step Check point
1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle
body for damage and dents. If the protective coating has been removed,
visually check the body paints for small areas of damage or stains.
(2) Visually check the glass and light lenses for any damage and cracks or
excessive gaps to the body sheet metal.
(3) Visually check the plated parts for any damage.
2. Tire check (1) Check the tires for damage, abnormal conditions, and dents on the
wheels.
(2) Check the tire air pressure.
3. Fuse installation If the vehicle is about to be delivered to the customer, attach a room light
fuse.
4. Connection of air conditioner harness If the vehicle is about to be delivered to the customer, connect the air condi-
tioner harness.
5. Check the doors for lock/unlock and open/close
operations.(1) Using the key, check if the door can be locked and unlocked normally.
(2) Open and close all doors to see that there are no abnormal conditions.
6. Operation check of double lock Check that the double lock operates normally.
7. Operation check of the child safety lock system. Check the child safety lock system operates normally.
8. Check the rear gate for lock/unlock and open/
close operations.(1) Check if the rear gate can be unlocked normally from the emergency
door.
(2) Open and close the rear gate to see that there are no abnormal condi-
tions.
(3) Operate the power door locking switch to check that the rear gate is
locked and unlocked normally.
9. Operation check of fuel lid opener lock release
leverOperate the fuel lid opener to check that the fuel lid is unlocked normally.
10. Accessory check Check that the following accessories are provided:
 Owner’s manual
 Warranty booklet
 Service booklet
 Spare key
Jack
Tool set
 Spare tire
11. Operation check of hood lock release system Operate the hood lock release lever to check that the hood opens normally.
12. Battery Check the battery for any abnormal conditions such as rust and trace of bat-
tery fluid leaks.
13. Brake fluid Check the fluid amount.
14. Engine oil Check the oil amount.
15. Transmission fluid (1) Check the fluid amount.
(2) For AT, check the front differential oil.
16. AT front differential oil Check the AT front differential oil amount.
17. Coolant Check the coolant amount.
18. Clutch fluid Check the clutch fluid amount.
19. Window washer fluid Check the window washer fluid amount.
20. Hood latch check Check that the hood is closed and latched securely.
21. Keyless entry system Check that the keyless entry system operates normally.
22. Security system Check that the security system operates normally.
23. Seat (1) Check the seat surfaces for smears or dirt.
(2) Check the seat installation conditions and functionality.
24. Seat belt Check the seat belt installation conditions and functionality.
25. Wheel alignment Check that the wheel alignments are properly adjusted.

PI-5
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
1. APPEARANCE CHECK
1) If the vehicle is covered with protective coating,
visually check the vehicle body for damage and
dents.
2) If there is no protective coating, check the body
paints for small areas of damage or stains and re-
pair as necessary.
3) Check the window glass, door glass, and lights
for any cracks or damage and repair or replace the
parts as necessary.
4) Check the plated parts, such as the grilles and
door knobs, for damage or loss of gloss and repair
or replace the parts as necessary.
2. TIRE CHECK
 Check the tire outer faces for any damage.
 Check the tire air pressure by referring to the fol-
lowing table.
3. FUSE INSTALLATION
A vehicle just delivered has no fuse for the room
lamp circuit to prevent battery discharge. Attach a
15 A fuse (A) as shown in the figure.
4. CONNECTION OF AIR CONDITIONER
HARNESS
A vehicle just delivered has its air conditioner har-
ness disconnected to protect the air conditioner
compressor. Connect the harness as shown in the
figure.
5. CHECK THE DOORS FOR LOCK/UN-
LOCK AND OPEN/CLOSE OPERATIONS.
1) Using the key, lock and unlock the door several
times to check for normal operation. Open and
close the door several times for smooth movement.Tire sizeTire inflation pressure
kPa (kg/cm2, psi)
Front Rear
205/70R15
200 (2.0, 29) 190 (1.9, 28) 215/60R16
P215/60R16
PI-00001(A)
(A) Unlock
(B) Lock
PI-00002
PI-00070
(A)
(B)

ME(H4SO)-53
MECHANICAL
Cam Sprocket
16.Cam Sprocket
A: REMOVAL
1. REMOVAL
1) Remove the V-belt. MOVAL, V-belt.>
2) Remove the crank pulley. 45, REMOVAL, Crank Pulley.>
3) Remove the belt cover. REMOVAL, Timing Belt Cover.>
4) Remove the timing belt assembly. ME(H4SO)-48, REMOVAL, Timing Belt.>
5) Remove the camshaft position sensor. FU(H4SO)-27, REMOVAL, Camshaft Position
Sensor.>
6) Remove the cam sprocket No. 2. To lock the
camshaft, use ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.
7) Remove the cam sprocket No. 1. Use ST to lock
the camshaft.
ST 499207400 CAM SPROCKET WRENCH
B: INSTALLATION
1) Install the cam sprocket No. 1. To lock the cam-
shaft, use ST.
ST 499207400 CAM SPROCKET WRENCH
Tightening torque:
78 N
⋅m (8.0 kgf-m, 57.9 ft-lb)
NOTE:
Do not confuse the right and left side cam sprock-
ets during installation. The cam sprocket No. 2 is
identified by a projection used to monitor camshaft
position sensor.
2) Install the cam sprocket No. 2. Use ST to lock
camshaft.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.
Tightening torque:
78 N
⋅m (8.0 kgf-m, 57.9 ft-lb)
3) Install the camshaft position sensor. FU(H4SO)-27, INSTALLATION, Camshaft Position
Sensor.>
4) Install the timing belt assembly. ME(H4SO)-49, INSTALLATION, Timing Belt.>
5) Install the belt cover. STALLATION, Timing Belt Cover.>
6) Install the crank pulley. INSTALLATION, Crank Pulley.>
7) Install the V-belt. STALLATION, V-belt.>
ME-00250
ST
ME-00251
ST
ME-00251
ST
ME-00250
ST

ME(H4SO)-72
MECHANICAL
Cylinder Block
29) Draw out the piston pin from #1 and #2 pistons
using ST.
ST 499097700 PISTON PIN REMOVER
NOTE:
Be careful not to confuse the original combination
of piston, piston pin and cylinder.30) Similarly remove the piston pins from #3 and #4
pistons.
31) Remove the bolts which connect cylinder block
on the side of #2 and #4 cylinders.
32) Back off the bolts which connect cylinder block
on the side of #1 and #3 cylinders two or three
turns.
33) Set up the cylinder block so that #1 and #3 cyl-
inders are on the upper side, and then remove the
cylinder block connecting bolts.
34) Separate the cylinder blocks (RH) and (LH).
NOTE:
When separating the cylinder block, do not allow
the connecting rod to fall and damage the cylinder
block.
35) Remove the rear oil seal.
36) Remove the crankshaft together with connect-
ing rod.
37) Remove the crankshaft bearings from cylinder
block using hammer handle.
NOTE:
Do not confuse the combination of crankshaft bear-
ings. Press bearing at the end opposite to locking
lip.38) Draw out each piston from cylinder block using
wooden bar or hammer handle.
NOTE:
Do not confuse the combination of piston and cylin-
der.
ME-00142
ST
(1) Cylinder block (3) Crankshaft (5) Piston
(2) Rear oil seal (4) Crankshaft bearing
ME-00143
(2)
(3)(4)
(4) (5)
(5) (1) (1)