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
(DIAGNOSTIC)
CC(H4DOTC 2.5)
Page
1. Basic Diagnostic Procedure ........................................................................2
2. General Description ....................................................................................4
3. Electrical Components Location..................................................................5
4. Engine Control Module (ECM) I/O Signal ...................................................6
5. Subaru Select Monitor.................................................................................8
6. Diagnostic Procedure with Symptom ........................................................10
7. List of Diagnostic Trouble Code (DTC) .....................................................13
8. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................16

CC(H4DOTC 2.5)-2
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Basic Diagnostic Procedure
1. Basic Diagnostic Procedure
A: PROCEDURE
Step Check Yes No
1 CHECK MALFUNCTION INDICATOR LIGHT.
Check the malfunction indicator light illumi-
nates.Does the malfunction indicator
light illuminate?Go to step 5.Go to step 2.
2 CHECK CRUISE INDICATOR LIGHT.
Check the cruise indicator light blinks.Does the cruise indicator light
blink?Go to step 5.Go to step 3.
3 CHECK CRUISE CONTROL MAIN SWITCH
OPERATION.
Check the cruise control main switch opera-
tion. (Check the cruise indicator light illumi-
nates.)Is the cruise control main
switch set to on? (Does the
cruise indicator light illumi-
nate?)Go to step 4.Go to symptom 1.
CC(H4DOTC 2.5)-
10, SYMPTOM
CHART, Diagnos-
tic Procedure with
Symptom.>
4 CHECK CRUISE CONTROL SET OPERA-
TION.
Check the cruise control set operation.Can the cruise control be set
while driving at 40 km/h (25
MPH)?Go to step 6.Go to step 5.
5 PERFORM CRUISE CONTROL CANCEL
CONDITION DIAGNOSIS.
Perform the cruise control cancel condition
diagnosis.Are any DTC indicated? Go to “List of
DTC”. CC(H4DOTC 2.5)-
13, List of Diag-
nostic Trouble
Code (DTC).>Go to symptom 2.
CC(H4DOTC 2.5)-
10, SYMPTOM
CHART, Diagnos-
tic Procedure with
Symptom.>
6 CHECK VEHICLE SPEED IS HELD WITHIN
SET SPEED.
Make sure the vehicle speed is held within set
speed.Is the vehicle speed held within
set speed ±3 km/h (±2 MPH)?
(Make an inspection on a level
road.)Go to step 7.Go to symptom 3.
CC(H4DOTC 2.5)-
10, SYMPTOM
CHART, Diagnos-
tic Procedure with
Symptom.>
7 CHECK RESUME/ACCEL OPERATION.
Check the RESUME/ACCEL switch operation.Does the vehicle speed
increase or return to set speed
after RESUME/ACCEL switch
has been pressed?Go to step 8.Go to symptom 4.
CC(H4DOTC 2.5)-
10, SYMPTOM
CHART, Diagnos-
tic Procedure with
Symptom.>
8 CHECK SET/COAST OPERATION.
Check the SET/COAST switch operation.Does the vehicle speed
decrease after SET/COAST
switch has been pressed?Go to step 9.Go to symptom 5.
CC(H4DOTC 2.5)-
10, SYMPTOM
CHART, Diagnos-
tic Procedure with
Symptom.>
9 CHECK CANCEL OPERATION.
Check the CANCEL switch operation.Is the cruise control released
after CANCEL switch has been
pressed?Go to step 10.Go to symptom 6.
CC(H4DOTC 2.5)-
10, SYMPTOM
CHART, Diagnos-
tic Procedure with
Symptom.>

CC(H4DOTC 2.5)-3
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Basic Diagnostic Procedure
10 CHECK CRUISE CONTROL RELEASE OP-
ERATION.
Check the cruise control release operation.Is the cruise control released
after brake pedal has been
depressed?Go to step 11.Go to symptom 7.
CC(H4DOTC 2.5)-
10, SYMPTOM
CHART, Diagnos-
tic Procedure with
Symptom.>
11 CHECK CRUISE CONTROL RELEASE OP-
ERATION.
Check the cruise control release operation.Is the cruise control released
after clutch pedal has been
depressed?Go to step 12.Go to symptom 8.
CC(H4DOTC 2.5)-
10, SYMPTOM
CHART, Diagnos-
tic Procedure with
Symptom.>
12 CHECK CRUISE CONTROL RELEASE OP-
ERATION.
Check the cruise control release operation.Is the cruise control released
after shifting to neutral posi-
tion?Finish the diagno-
sis.Go to symptom 9.
CC(H4DOTC 2.5)-
10, SYMPTOM
CHART, Diagnos-
tic Procedure with
Symptom.> Step Check Yes No

CC(H4DOTC 2.5)-4
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
General Description
2. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”
Airbag system wiring harness is routed near the cruise control command switch.
CAUTION:
 All airbag system wiring harness and connectors are colored yellow. Do not use electrical test
equipment on these circuits.
 Be careful not to damage the airbag system wiring harness when servicing the cruise control com-
mand switch.
B: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
C: INSPECTION
1. BATTERY
Measure the battery voltage and specific gravity of electrolyte.
Standard voltage:
12 V, or more
Specific gravity:
Above 1.260
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical systems.
22771AA030 SUBARU SELECT
MONITOR KITTroubleshooting for electrical systems.
English:
22771AA030 (Without printer)
German:
22771AA070 (Without printer)
 French:
22771AA080 (Without printer)
 Spanish:
22771AA090 (Without printer)
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and ampere.
ST24082AA230
ST22771AA030

CC(H4DOTC 2.5)-5
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Electrical Components Location
3. Electrical Components Location
A: LOCATION
(1) Inhibitor switch (AT model) (4) Clutch switch (MT model) (7) Neutral switch (MT model)
(2) Cruise control command switch (5) Stop light and brake switch
(3) Cruise control main switch (6) Engine control module (ECM)
(1)
(2)
(3)
(4) (6)(7)
CC-00262 (5)

CC(H4DOTC 2.5)-6
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Engine Control Module (ECM) I/O Signal
4. Engine Control Module (ECM) I/O Signal
A: ELECTRICAL SPECIFICATION
ContentTe r m i n a l
No.Measuring conditions and I/O signals (ignition switch ON and engine idling)
Clutch switch A1 Battery voltage is present when the clutch pedal is released.
 “0 V” volt is present when the clutch pedal is depressed.
Cruise indicator light A15 Battery voltage is present when the main switch is turned to OFF.
 “0 V” volt is present when the main switch is turned to ON.
Main power
supplyVB (CONTROL 1)
VB (CONTROL 2)B6
B5 Battery voltage is present when the main power supply is turned to ON.
 “0 V” volt is present when the main power supply is turned to OFF.
Vehicle speed signal B26Lift-up the vehicle until all four wheels are raised off the ground, and then rotate
any wheel manually. Approx. “5 V” and “0 V” pulse signals are alternately input to
ECM.
SET/COAST switch C11 Battery voltage is present when the command switch is turned to SET/COAST
position.
 “0 V” volt is present when the command switch is released.
RESUME/ACCEL switch C10 Battery voltage is present when the command switch is turned to RESUME/
ACCEL position.
 “0 V” volt is present when the command switch is released.
Brake switch 1
(Brake switch)C9 Battery voltage is present when the brake pedal is released.
 “0 V” volt is present when the brake pedal is depressed.
Brake switch 2
(Stop light switch)C8 Battery voltage is present when the brake pedal is depressed.
 “0 V” volt is present when the brake pedal is released.
Main switch C7 Battery voltage is present while the main switch is depressed or is turned to
ON.
 “0 V” volt is present when the main switch is turned to OFF.
GroundGND (CONTROL 1)
GND (CONTROL 2)D2
D1—
Ignition switch D15 Battery voltage is present with the ignition switch is turned to ON.
 “0 V” volt is present when the ignition switch is turned to OFF.
Neutral switch (MT model) D9 Battery voltage is present when the shift lever is in anywhere except neutral
position.
 “0 V” volt is present when the shift lever is in neutral position.
Inhibitor switch (AT model) D9 “0 V” volt is present when the select lever is in anywhere except N or P posi-
tion.
 “5 V” volt is present when the select lever is in N or P position.
CC-00197
B134
9
30 29 28 32 3120 19 18 22 2110 12 1114
24
34 3327 2617 16123456713
23 15
258
B135
9
30 29 28
323120 22 2110 12 1114
24
35
3327 2617 16123456713
23 15
258
B136
9
30 29 28
32 3120 19 18 22 2110 12 1114
24
34 3327 261612345613
23 15
258
B137
9
29 2820 19 18 22
2110 12
1114
2417 16123456713
23 15
2581819
34
7173530 3127 26
To D: To C: To B: To A:

CC(H4DOTC 2.5)-7
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Engine Control Module (ECM) I/O Signal
B: WIRING DIAGRAM

CC(H4DOTC 2.5)-8
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Subaru Select Monitor
5. Subaru Select Monitor
A: OPERATION
1. GENERAL
The on-board diagnosis function of the cruise con-
trol system uses the Subaru Select Monitor.
The on-board diagnosis function operates in two
categories, which are used depending on the type
of problems;
1) Cruise cancel conditions diagnosis:
(1) This category of diagnosis requires actual ve-
hicle driving in order to determine the cause, (as
when cruise speed is cancelled during driving al-
though cruise cancel condition is not entered).
(2) Cruise control memory of ECM stores the
cancel condition (Code No.) which occurred dur-
ing driving. When there are plural cancel condi-
tions (Code No.), they are shown on the Subaru
Select Monitor.
CAUTION:
 The cruise control memory stores not only the
cruise “cancel” which occurred (although “can-
cel” operation is not entered by the driver), but
also the “cancel” condition input by the driver.
 The content of memory is cleared when igni-
tion switch or cruise main switch is turned OFF.
2) Real-time diagnosis:
The real-time diagnosis function is used to deter-
mine whether or not the input signal system is in
good order, according to signal emitted from
switches, sensors, etc.
(1) Vehicle cannot be driven at cruise speed be-
cause problem occurs in the cruise control sys-
tem or its associated circuits.
(2) Monitor the signal conditions from switches
and sensors.
2. CRUISE CANCEL CONDITIONS DIAG-
NOSIS
1) Prepare the Subaru Select Monitor kit.
2) Connect the diagnosis cable to Subaru Select
Monitor.3) Insert the cartridge into Subaru Select Monitor.
PREPARATION TOOL, General Description.>
4) Connect the Subaru Select Monitor to data link
connector.
(1) Data link connector is located in the lower
portion of the instrument panel (on the driver’s
side).
(2) Connect the diagnosis cable to data link
connector.
5) Start the engine and turn the cruise control main
switch to ON.
6) Turn the Subaru Select Monitor switch to ON.
7) On the «Main Menu» display screen, select the
{2. Each System Diagnosis} and press [YES] key.
Select the {Engine} on the System Selection dis-
play screen and press [YES] key. Press [YES] key
after the engine type displayed.
8) Drive the vehicle at least 40 km/h (25 MPH) with
cruise speed set.
CC-00028
(1) Power switch
CC-00029
CC-00134
CC-00045
(1)