ECU SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 1 of 2870
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
Page 22 of 2870
AC-20
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
C: CAUTION
1. HFC-134a A/C SYSTEM
The cooling system components for the HFC-
134a system such as the refrigerant and compres-
sor oil are different from the old conventional HFC-
12 system components and they are incompatible
with each other.
Vehicles with the HFC-134a system can be iden-
tified by the label (A) attached to the vehicle.
Before maintenance, check which A/C system is in-
stalled in the vehicle.
2. COMPRESSOR OIL
HFC-134a compressor oil has no compatibility
with that for R12 system.
Use only the manufacturer-authorized compres-
sor oil for the HFC-134a system; only use
ZXL200PG.
Do not mix multiple compressor oils.
If HFC-12 compressor oil is used in a HFC-134a A/
C system, the compressor may become stuck due
to poor lubrication, or the refrigerant may leak due
to swelling of rubber parts.
On the other hand, if HFC-134a compressor oil is
used in a HFC-12 A/C system, the durability of the
A/C system will be lowered.
HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from the atmosphere us-
ing a plug or tape. In order to avoid moisture, store
the oil in a container with its cap securely closed.
3. REFRIGERANT
The HFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the HFC-12 A/C system.
If an incorrect or no refrigerant is used, poor lu-
brication will result and the compressor itself may
be damaged.
4. HANDLING OF REFRIGERANT
The refrigerant boils at approx. −30°C (−22°F).
When handling it, be sure to wear safety goggles
and protective gloves. Direct contact of the refriger-
ant with skin may cause frostbite.
If the refrigerant gets into your eye, avoid rubbing
your eyes with your hands. Wash your eye with
plenty of water, and receive medical treatment from
an eye doctor.
Do not heat a service can. If a service can is di-
rectly heated, or put into boiling water, the inside
pressure will become extremely high. This may
cause the can to explode. If a service can must be
warmed up, use hot water in 40°C (104°F) max.
Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
When the engine is running, do not open the
high-pressure valve of the manifold gauge. The
high-pressure gas will back-flow resulting in an ex-
plosion of the can.
Provide good ventilation and do not work in a
closed area.
In order to prevent global warming, avoid releas-
ing HFC-134a into the atmosphere. Using a refrig-
erant recovery system, discharge and reuse it.
AC-00006
(A)
(A) Goggles
(B) Gloves
(C) Avoid open flame
(D) No direct heat on container
(E) Do not discharge
(F) Loosen
(A)
(B)
(C) (D)
(E) (F)
AC-00007
Page 29 of 2870
AC-27
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Charging Procedure
4. Refrigerant Charging Proce-
dure
A: OPERATION
CAUTION:
During operation, be sure to wear safety gog-
gles and protective gloves.
If air is mixed in refrigeration cycle, poor cool-
ing may result, and also if moisture is mixed in re-
frigeration cycle, clogging (freezing) or rust may
result.
Before charging the refrigerant, evacuate the
system using vacuum pump to remove air and
moisture in the system. Moisture can be evapo-
rated and removed easily even at normal tem-
perature, if the system is evacuated using
vacuum pump.
1) Close all valves of manifold gauge.2) Install the low-/high-pressure hoses to corre-
sponding service ports on vehicle.
CAUTION:
Be sure that the hoses are securely connected.
3) Connect the center hose of manifold gauge with
vacuum pump.
4) Activate the vacuum pump and then open the
valves on low-/high-pressure sides.
CAUTION:
Be sure to evacuate the system using vacuum
pump.
5) After at least 5 minutes of evacuation, if the low-
pressure gauge reading shows 100.0 kPa (750
mmHg, 29.5 inHg) or higher, close the valves on
center hose to stop the vacuum pump.
L: Low-pressure gauge
H: High-pressure gauge
(1) Low-pressure valve
(2) Vacuum pump valve
(3) High-pressure valve
(4) For low-pressure
(5) For vacuum pump
(6) For high-pressure
AC-00146
(2) (4)
(5)(6)
(3)(3)
(2) (1)H L
(1)
(1) Low-pressure service port
(2) High-pressure service port
(3) Close
(1) Vacuum pump
(2) Open
AC-00147
(3) (2) (1)
AC-00148
(1)(2)
Page 41 of 2870
AC-39
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Heater Cooling Unit
14.Heater Cooling Unit
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Using the refrigerant recovery system, dis-
charge refrigerant.
3) Drain the engine coolant from radiator.
4) Remove the bolt securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to remove the
hoses.
5) Remove the instrument panel.
6) Remove the support beam.
7) Remove the blower motor unit assembly.
bly.>
8) Disconnect the servo motor connectors.
9) Remove the bolt and nuts to remove the heater
and cooling unit.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Charge refrigerant.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
AC-00870
AC-00055
Page 55 of 2870
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
Page 99 of 2870
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
Page 104 of 2870
AB-4
AIRBAG SYSTEM
General Description
Do not drop the airbag modulator parts, subject
them to high temperature over 93°C (199°F), or let
water, oil, or grease get on them; otherwise, the in-
ternal parts may be damaged and reliability greatly
lowered.
If any damage, opening, or rust is found on the
airbag system wire harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
Install the wire harness securely with the speci-
fied clips to avoid interference or tangled up with
other parts. Do not allow water or oil to come in contact with
the connector terminals. Do not touch the connec-
tor terminals.
Either of the airbag modules for driver, passen-
ger or side, or pretensioner must not be disassem-
bled.
The removed front seat with the airbag module
must be kept at least 200 mm (8 in) away from walls
and other objects.
Do not use the airbag or pretensioner parts from
other vehicles. Always replace defective parts with
new ones.
Never reuse a deployed airbag or pretensioner.
When painting or performing sheet metal work
on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame, re-
move the front sub sensors and wire harness of the
airbag system.
AB-00123
AB-00124
AB-00125
(1) More than 200 mm (8 in)
AB-00126
AB-00779
AB-00128
(1)
Page 111 of 2870
AB-11
AIRBAG SYSTEM
Airbag Connector
(2) With the slide lock pushed, pull the connec-
tor in the direction of arrow and disconnect it.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
6. LAP SEAT BELT PRETENSIONER
1) How to disconnect:
(1) Using a flat tip screwdriver, pry the push
lock (A) upward to unlock.(2) Pull the connector to disconnect from lap
seat belt pretensioner.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Connect the connector in reverse order of discon-
necting. At this time, be sure to insert the connector
in until a connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it
locks.
Then pull it gently to make sure that it is locked.
Be sure to lock the push lock securely.
AB-00022
AB-00023
AB-00115
(A)
AB-00026
AB-00027
Page 117 of 2870
AB-17
AIRBAG SYSTEM
Side Airbag Module
3) Install the side airbag harness to backrest frame
assembly.
NOTE:
Secure the harness to its original position of seat.
4) Install the backrest cover.
5) Install the side airbag harness to slide rail IN (A).
6) Recline the seat or slide it backward and for-
ward. Check there is no contact between seat
backrest assembly, cushion cover assembly and
side airbag harness. C: INSPECTION
CAUTION:
Before working on the airbag module, refer to
the “CAUTION” in General Description.
Perform the inspection of following items, and replace
the damaged parts with new ones.
tion Locations After a Collision.>
1) With side clash (when side airbag is deployed)
Side airbag module assembly
Backrest pad assembly
Backrest frame assembly
Backrest cover assembly
Headrest assembly
Bushing
Slide rail OUT
Slide rail IN
Seat hinge cover
Seat lifter lever
Reclining lever
Side airbag harness and connector (body side)
2) With side clash (when side airbag is not de-
ployed)
Check the seat and airbag module visually, and
then replace them with new ones if damaged or
cracked.
Specially inspect the damage of airbag module
body, installing bracket, harness connector.
3) Without side clash (dirt and damage of cover)
Replace the corresponding part with a new one.
AB-00475
AB-00474
(A)
Page 123 of 2870
AB-23
AIRBAG SYSTEM
Airbag Module Disposal (Deployment Processing On Vehicle)
8) Extend the wiring of deployment tool to the limit,
and make sure that the vehicle is empty. Close all
the windows, sunroof and rear gate completely.
9) Move the battery at least 5 m (16 ft) from vehicle,
and secure the nearby area. Connect the deploy-
ment tool alligator clip to the battery negative (−)
terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the air-
bag module.
CAUTION:
After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
Do not let water get on the deployed airbag
module.
11) Remove the airbag module.
12) Wrap the deployed airbag module in airtight vi-
nyl bag, and discard it.2. PASSENGER’S AIRBAG MODULE
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
3) Remove the glove box.
4) Disconnect the airbag connectors (AB4) and
(AB27).
5) Short the terminal to alligator clip furnished as
deployment tool (A)
6) Connect the deployment tool (A) and deploy-
ment adapter E (B).
CAUTION:
The deployment tool should be kept shorted
terminals until just before deployment of airbag
module.
7) Connect the deployment adapter E to the airbag
connector (AB27).
SB-00017
SB-00018
AB-00043
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter E:
(Tool number 98299SA030)
(1) Deployment adapter E:
(Tool number 98299SA030)
SB-00016
AB-00199
AB27
(1)