light SUBARU FORESTER 2004 Service Manual PDF

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

LIGHTING SYSTEM
LI
Page
1. General Description ....................................................................................2
2. Headlight and Tail Light System .................................................................3
3. Front Fog Light System ...............................................................................4
4. Rear Fog Light System ...............................................................................5
5. Turn Signal Light and Hazard Light System................................................6
6. Back-up Light System .................................................................................7
7. Stop Light System .......................................................................................8
8. Room Light System .....................................................................................9
9. Headlight Beam Leveler System ...............................................................10
10. Combination Switch (Light) .......................................................................11
11. Headlight Assembly ..................................................................................13
12. Headlight Bulb ...........................................................................................16
13. Front Turn Signal Light Bulb .....................................................................17
14. Clearance Light Bulb .................................................................................18
15. Front Fog Light Assembly .........................................................................19
16. Front Fog Light Bulb..................................................................................20
17. Rear Combination Light Assembly ............................................................21
18. Tail/Stop Light Bulb ...................................................................................22
19. Back-up Light Bulb ....................................................................................23
20. Rear Turn Signal Light Bulb ......................................................................24
21. Rear Fog Light Bulb ..................................................................................25
22. License Plate Light ....................................................................................26
23. High-mounted Stop Light ..........................................................................27
24. Side Turn Signal Light ...............................................................................28
25. Spot Map Light ..........................................................................................29
26. Room Light ................................................................................................30
27. Luggage Room Light .................................................................................31
28. Glove Box Light .........................................................................................32

LI-2
LIGHTING SYSTEM
General Description
1. General Description
A: SPECIFICATION
B: PRECAUTIONS
 Before removing and installing parts, always disconnect the battery ground cable. When replacing audio,
control module, and other parts provided with memory functions, record memory contents before disconnect-
ing the battery ground cable. Otherwise, the memory will be erased.
 Reassemble in reverse order of disassembly, unless otherwise indicated.
 Adjust parts to the given specifications.
 Connect the connectors and hoses securely during reassembly.
 After reassembly, make sure functional parts operate smoothly.
WARNING:
 Airbag system wiring harness is routed near electrical parts and switches. All airbag system wiring
harnesses and connectors are yellow. Do not use electric test equipment on these circuits.
 Be careful not to damage the airbag system wiring harness when servicing electrical parts and
switches.
C: PREPARATION TOOL
1. GENERAL TOOL
Headlight12 V — 55 W/60 W
Front turn signal light 12 V — 21 W
Clearance light12 V — 5 W
Side marker light12 V — 5 W
Front fog light12 V — 55 W
Rear combination lightTail/Stop light 12 V — 5/21 W
Turn signal light 12 V — 21 W
Back-up light 12 V — 16 W
License plate light12 V — 5 W
High-mounted stop lightStandard type 12 V — 13 W
Rear spoiler built-in type 12 V — 1.2 W
Room light12 V — 8 W
Spot light12 V — 8 W
Luggage room light12 V — 5 W
TOOL NAME REMARKS
Circuit tester Used for measuring resistance and voltage.

LI-3
LIGHTING SYSTEM
Headlight and Tail Light System
2. Headlight and Tail Light Sys-
tem
A: WIRING DIAGRAM
1. HEADLIGHT
System.>
2. CLEARANCE LIGHT AND ILLUMINA-
TION LIGHT
Light and Illumination Light System.>
B: INSPECTION
1. HEADLIGHT SWITCH
(Light).>
2. HEADLIGHT RELAY
Measure the headlight relay resistance between
terminals when connecting terminal No. 4 to battery
positive terminal and terminal No. 3 to battery
ground terminal.
3. TAIL AND ILLUMINATION RELAY
Measure the tail and illumination relay resistance
between terminals when connecting terminal No. 4
to battery positive terminal and terminal No. 3 to
battery ground terminal.
Current Terminal No. Standard
Flow
1 and 2Less than 1 Ω
No flow More than 1 MΩ
LI-00001
(1)
(2) (1)
(4)(2)
(3)
(3)(4)
Current Terminal No. Standard
Flow
1 and 2Less than 1 Ω
No flow More than 1 MΩ
LI-00001
(1)
(2) (1)
(4)(2)
(3)
(3)(4)

LI-4
LIGHTING SYSTEM
Front Fog Light System
3. Front Fog Light System
A: WIRING DIAGRAM
1. FRONT FOG LIGHT
Light System.>
B: INSPECTION
1. FRONT FOG LIGHT SWITCH
Measure the resistance between front fog light switch
terminals.
2. FRONT FOG LIGHT RELAY
Measure the front fog light relay resistance be-
tween terminals when connecting terminal No. 4 to
battery positive terminal and terminal No. 3 to bat-
tery ground terminal.
Switch position Terminal No. Standard
OFF
3 and 5More than 1 MΩ
ON Less than 1 Ω
Current Terminal No. Standard
Flow
1 and 2Less than 1 Ω
No flow More than 1 MΩ
LI-00051
LI-00001
(1)
(2) (1)
(4)(2)
(3)
(3)(4)

LI-5
LIGHTING SYSTEM
Rear Fog Light System
4. Rear Fog Light System
A: WIRING DIAGRAM
1. REAR FOG LIGHT
Light System.>
B: INSPECTION
1. REAR FOG LIGHT SWITCH
1) Turn the ignition switch to ON.
2) Turn on the headlight or front fog light.
3) Push the rear fog light switch and check if the
rear fog light turns on.
2. REAR FOG LIGHT RELAY
Measure the rear fog light relay resistance between
terminals when connecting terminal No. 4 to battery
positive terminal and terminal No. 3 to battery
ground terminal.
Current Terminal No. Standard
Flow
1 and 2Less than 1 Ω
No flow More than 1 MΩ
LI-00001
(1)
(2) (1)
(4)(2)
(3)
(3)(4)

LI-6
LIGHTING SYSTEM
Turn Signal Light and Hazard Light System
5. Turn Signal Light and Hazard
Light System
A: WIRING DIAGRAM
1. TURN SIGNAL LIGHT AND HAZARD
LIGHT
Light and Hazard Light System.>
B: INSPECTION
1. TURN SIGNAL SWITCH
(Light).>
2. HAZARD SWITCH
Measure the resistance between hazard switch ter-
minals.
3. TURN SIGNAL AND HAZARD MODULE
Connect the battery and the turn signal light bulb to
module, as shown in the figure. The module is
properly functioning if it blinks when power is sup-
plied to the circuit.
Switch position Terminal No. Standard
OFF 6 and 7 Less than 1 Ω
ON1, 3 and 4 Less than 1 Ω
7 and 8 Less than 1 Ω
LI-00002
43 21
5 6 7 8
LI-00003

LI-7
LIGHTING SYSTEM
Back-up Light System
6. Back-up Light System
A: WIRING DIAGRAM
1. BACK-UP LIGHT
Light System.>
B: INSPECTION
1. BACK-UP LIGHT SWITCH (MT MODEL)
Measure the resistance between back-up light switch
terminals.
2. INHIBITOR SWITCH (AT MODEL)
Measure the resistance between inhibitor switch ter-
minals.
(A) Non-turbo model
(B) Turbo model
Switch position Terminal No. Standard
When shift lever is
set in reverse
positionNon-turbo model:
1 and 2
Turbo model:
2 and 4Less than 1 Ω
Other positions More than 1 MΩ
LI-00317 1 2
1 2
3 4
(A)
(B)Switch position Terminal No. Standard
When select lever
is set in “R” range
1 and 2Less than 1 Ω
Other positions More than 1 MΩ
9
LI-000054321 5 6
7 8 10 11 12

LI-8
LIGHTING SYSTEM
Stop Light System
7. Stop Light System
A: WIRING DIAGRAM
1. STOP LIGHT
System.>
B: INSPECTION
1. STOP LIGHT SWITCH
Measure the resistance between stop light switch
terminals.
(A) Without cruise control
(B) With cruise control
Switch position Terminal No. Standard
When brake pedal
is depressed1 and 2:
Without cruise
control
2 and 3:
With cruise controlLess than 1 Ω
When brake pedal
is releasedMore than 1 MΩ
3 4
1 2
1 2
LI-00064
(A)
(B)

LI-9
LIGHTING SYSTEM
Room Light System
8. Room Light System
A: WIRING DIAGRAM
1. ROOM LIGHT
ment Light System.>
B: INSPECTION
1. DOOR SWITCH
Measure the resistance between door switch termi-
nals.
2. REAR GATE LATCH SWITCH
Measure the resistance between rear gate latch
switch terminals.
Switch position Terminal No. Standard
When door is
open
1 and 3Less than 1 Ω
When door is
closedMore than 1 MΩ
Switch position Terminal No. Standard
When rear gate is
open
1 and 2Less than 1 Ω
When rear gate is
closedMore than 1 MΩ
123
LI-00007