warning SUBARU FORESTER 2004 Service Manual Online

IM-5
IMMOBILIZER (DIAGNOSTIC)
Electrical Components Location
3. Electrical Components Location
A: LOCATION
NOTE:
IMM ECM location for RHD model is symmetrically
opposite.
(1) Antenna (3) Immobilizer control module (IMM
ECM)(4) Transponder
(2) Immobilizer warning light (LED)
IM-00004
(1)
(2)
(3)(4)

IM-10
IMMOBILIZER (DIAGNOSTIC)
Diagnostics Chart for Immobilizer Warning Light
8. Diagnostics Chart for Immobilizer Warning Light
A: INSPECTION
1. CHECK IMMOBILIZER WARNING CIRCUIT
WIRING DIAGRAM:
IM-00081
F60
B21
RHD
SBF-1
SBF-5SBF-4
BATTERY
IMMOBILIZER
WARNING
LIGHT COMBINATION METER
B141IMM ECM
B37
i2
i2
B37
i12
B37
i2
LHD
RHDLHD
6
RHD
M/B No.2
F/B No.11
IGNITION
SWITCH
91211102
B8
3: RHD MODEL
1: Non-turbo AT MODEL: 14
: MT MODEL AND
TURBO AT MODEL:4
i12B141
34 12
89
10 11125
67
219
32
B38
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
25
123456789101112131415161718192021222324252627282930
LHDB37
34 12 89
10 11
12 13 14 15 16 17 18 19 20 21 22 23 24567
i10
1
23456789
10
B:
E
A:i10 B:
i11C:
: LHD TURBO MODELLT
: EXCEPT LHD TURBO MODEL
XL
34 12 8910
1112 13 14 15 161718
19 20 21 22567
i2RHD
F2LHD
LHD
LHD
7
F44B61
RHD
RHD
LHD
: LHD MODEL
1
2
i11 C:
LHD
LHD
18
i3
B38
RHD
RHD
3
XL
LT
XL
LT9
1616
F2B100
B21
E2
F60
E3
LHD
RHD
2: LHD MODEL: A4
: RHD MODEL: C5
3: Non-turbo AT MODEL: 22
: MT MODEL AND
TURBO AT MODEL: 18
A:
:
AT:
23 1789 1011121314 15
16 1718456
i2RHDMT:
1234 5678910 11 12 13 14 15 16 17 18 19 20123
4
56
78
9
1011 12
1314 15 16
1234568791011121314
F44
12345678

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-12
IMMOBILIZER (DIAGNOSTIC)
Diagnostics Chart for Immobilizer Warning Light
2. CHECK KEY WARNING SWITCH CIRCUIT
WIRING DIAGRAM:
IM-00006
B74
B61
F44
KEY WARNING
SWITCH
B141IMM ECM
LHD
RHDLHD
RHD
BATTERYM/B No.6
4
12
4
B74
1
2
B141
34 12
89
10 11125
67
F44
3
1
56
78
LHD: LHD MODEL
: RHD MODEL
RHD
2
4

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.

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.

PM-21
PERIODIC MAINTENANCE SERVICE
Engine Coolant
12.Engine Coolant
A: REPLACEMENT
1. REPLACEMENT OF ENGINE COOLANT
WARNING:
The radiator is of the pressurized type. Do not
attempt to open the radiator cap immediately
after the engine has been stopped.
1) Lift-up the vehicle.
2) Remove the under cover.
3) Place a container under drain pipe.
4) Loosen and remove the drain cock to drain en-
gine coolant into container.
5) For quick draining, open the radiator cap.
CAUTION:
Be careful not to spill coolant on the floor.
6) Drain the coolant from reservoir tank.
7) Tighten the radiator drain cock securely after
draining coolant.
8) Slowly pour the engine coolant from radiator fill-
er port to neck of filler, then pour into reservoir tank
up to “FULL” level.
Coolant capacity (fill up to “FULL” level)
2.0 L Non-turbo AT model:
Approx. 6.52 (6.9 US qt, 5.7 Imp qt)
2.0 L Non-turbo MT model:
Approx. 6.62 (7.0 US qt, 5.8 Imp qt)
2.0 L Non-turbo model with ATF warmer:
Approx. 6.92 (7.3 US qt, 6.1 Imp qt)
2.0 L 2.5 L Turbo AT and MT with oil cooler
model:
Approx. 7.32 (7.7 US qt, 6.4 Imp qt)
2.0 L 2.5 L Turbo MT without oil cooler model:
Approx. 7.42 (7.8 US qt, 6.5 Imp qt)
2.5 L AT model:
Approx. 6.82 (7.2 US qt, 6.0 Imp qt)
2.5 L MT model:
Approx. 6.92 (7.3 US qt, 6.1 Imp qt)NOTE:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crank-
case. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.
9) Securely install the radiator cap.
10) Run the engine for more than 5 minutes at
2,000 to 3,000 rpm. (Run the engine until radiator
becomes hot in order to purge the air trapped in
cooling system.)
11) Stop the engine and wait until coolant temper-
ature lowers. Then open the radiator cap to check
coolant level and add coolant up to radiator filler
neck. Next, add coolant into reservoir tank up to
“FULL” level.
12) After adding coolant, securely install the radia-
tor and reservoir tank caps.
CO-00009

FU(H4SO)-16
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
16) Disconnect the connector from the oil pressure
switch.
17) Disconnect the connector from the camshaft
position sensor.
18) Remove the EGR pipe from intake manifold.19) Disconnect the fuel hoses from the fuel pipes.
WARNING:
 Do not spill fuel.
 Catch fuel from hoses in a container or cloth.
20) Remove the bolts which hold intake manifold
onto the cylinder heads.
21) Remove the intake manifold.
B: INSTALLATION
1) Install the intake manifold onto the cylinder
heads.
NOTE:
Replace the gaskets with new ones.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
FU-00146
FU-00147
FU-00148
(A) Fuel delivery hose
(B) Fuel return hose
(C) Evaporation hose
(B) (A)
(C)
FU-00259
FU-00260
FU-00260

FU(H4SO)-47
FUEL INJECTION (FUEL SYSTEM)
Fuel
19.Fuel
A: OPERATION
1. RELEASING OF FUEL PRESSURE
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Disconnect the connector from fuel pump relay.
2) Start the engine and run it until it stalls.
3) After the engine stalls, crank it for 5 more sec-
onds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Open the fuel filler flap lid and remove fuel filler
cap.
4) Lift-up the vehicle.5) Drain fuel from the fuel tank.
Set a container under the vehicle and remove the
drain plug from fuel tank.
6) Tighten the fuel drain plug.
Tightening torque:
26 N
⋅m (2.7 kgf-m, 19.2 ft-lb)
FU-00262
FU-00009
FU-00089
FU-00089

FU(H4SO)-48
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
20.Fuel Tank
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Set the vehicle on a lift.
2) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
3) Drain fuel from the fuel tank. 47, DRAINING FUEL, OPERATION, Fuel.>
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to
rear harness.
6) Push the grommet (B) which holds fuel tank cord
on floor panel into under the body.
7) Remove the rear crossmember. REMOVAL, Rear Crossmember.>
8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B)
from canister.9) Loosen the clamp and disconnect the fuel filler
hose and air vent hose from fuel filler pipe.
10) Move the clips, and disconnect quick connec-
tor. ery, Return and Evaporation Lines.>
11) Disconnect the fuel hoses.
12) Support the fuel tank with transmission jack,
and remove the bolts from bands and dismount fuel
tank from the vehicle.
WARNING:
A helper is required to perform this work.
(B)
(A)
FU-00090
(A)
(B)
FU-00091
FU-00092
FU-00093
FU-00411