Subaru forester 2004 Service Manual

Subaru forester 2004 Service Manual

Body section
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2004 FORESTER SERVICE MANUAL

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.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)
AIRBAG SYSTEM
AIRBAG SYSTEM (DIAGNOSTIC)
SEAT BELT SYSTEM
LIGHTING SYSTEM
WIPER AND WASHER SYSTEM
ENTERTAINMENT
COMMUNICATION SYSTEM
GLASS/WINDOW/MIRROR
BODY STRUCTURE
INSTRUMENTATION/DRIVER INFO
SEAT
SECURITY AND LOCK
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
EXTERIOR/INTERIOR TRIM
EXTERIOR BODY PANEL
AC
AC
AB
AB
SB
LI
WW
ET
COM
GW
BS
IDI
SE
SL
SR
EI
EB
G8080GE7

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Table of Contents
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Summary of Contents for Subaru forester 2004

  • Page 1: Body Section

    HVAC SYSTEM (AUTO A/C) (DIAGNOSTIC) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTIC) This service manual has been prepared to provide SUBARU service personnel SEAT BELT SYSTEM with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. LIGHTING SYSTEM...
  • Page 2 2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(H4SO) (DIAGNOSTIC) CRUISE CONTROL SYSTEM CC(H4DOTC) (DIAGNOSTIC) CRUISE CONTROL SYSTEM CC(H4DOTC 2.5) (DIAGNOSTIC) IMMOBILIZER (DIAGNOSTIC) G8080GE7...
  • Page 3: Table Of Contents

    Basic Diagnostic Procedure ................2 General Description ..................3 Electrical Components Location..............5 Immobilizer Control Module I/O Signal............6 Subaru Select Monitor.................7 Read Diagnostic Trouble Code (DTC) ............8 Clear Memory Mode..................9 Diagnostics Chart for Immobilizer Warning Light ........10 List of Diagnostic Trouble Code (DTC) .............14...
  • Page 4: Basic Diagnostic Procedure

    Repair the related 1) Turn the ignition switch to OFF. play? parts. 2) Connect the Subaru Select Monitor to data link connector. <Ref. to IM-7, Subaru Select Monitor.> 3) Turn the ignition switch and Subaru Select Monitors witch to ON.
  • Page 5: General Description

    General Description IMMOBILIZER (DIAGNOSTIC) 2. General Description • When repeatedly turning the ignition switch to ON or OFF while diagnostic items are being A: CAUTION checked, it should be switched in cycles of “ON” for at least 5 seconds → “OFF” for at least CAUTION: 8 seconds.
  • Page 6: Special Tool

    General Description IMMOBILIZER (DIAGNOSTIC) B: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOLNUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical systems. (Newly adopted tool) ST24082AA230 22771AA030 SUBARUSELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) •...
  • Page 7: Electrical Components Location

    Electrical Components Location IMMOBILIZER (DIAGNOSTIC) 3. Electrical Components Location A: LOCATION IM-00004 Antenna Immobilizer control module (IMM Transponder ECM) Immobilizer warning light (LED) NOTE: IMM ECM location for RHD model is symmetrically opposite. IM-5...
  • Page 8: Immobilizer Control Module I/O Signal

    Immobilizer Control Module I/O Signal IMMOBILIZER (DIAGNOSTIC) 4. Immobilizer Control Module I/O Signal A: WIRING DIAGRAM 1. IMMOBILIZER <Ref. to WI-194, WIRING DIAGRAM, Immobilizer System.> IM-6...
  • Page 9: Subaru Select Monitor

    1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the Subaru Select Monitor kit. CC-00045 (1) Power switch 6) Using the Subaru Select Monitor, call up any DTCs and various data, and then record them. CC-00028 2. READ DIAGNOSTIC TROUBLE CODE 2) Connect the diagnosis cable to Subaru Select (DTC) FOR ENGINE.
  • Page 10: Read Diagnostic Trouble Code (Dtc)

    {History Diagnostic Code(s)}, and then press the [YES] key. NOTE: • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MAN- UAL. • For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC).
  • Page 11: Clear Memory Mode

    {Clear Memory}, and then press the [YES] key. 5) When the `Done’ is shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: • After the memory has been cleared, the ISC must be initialized.To do this, turn the ignition switch to ON po-...
  • Page 12: Diagnostics Chart For Immobilizer Warning Light

    Diagnostics Chart for Immobilizer Warning Light IMMOBILIZER (DIAGNOSTIC) 8. Diagnostics Chart for Immobilizer Warning Light A: INSPECTION 1. CHECK IMMOBILIZER WARNING CIRCUIT WIRING DIAGRAM: BATTERY SBF-1 M/B No.2 IGNITION SWITCH SBF-5 SBF-4 F/B No.11 COMBINATION METER IMMOBILIZER WARNING LIGHT B100 LHD : LHD MODEL : RHD MODEL : LHD TURBO MODEL...
  • Page 13 Diagnostics Chart for Immobilizer Warning Light IMMOBILIZER (DIAGNOSTIC) Step Check CHECK IMMOBILIZER WARNING LIGHT. Does the immobilizer warning Go to step 2. Go to step 5. 1) Turn the ignition switch to OFF. light illuminate? 2) Disconnect the harness connector from IMM ECM.
  • Page 14 Diagnostics Chart for Immobilizer Warning Light IMMOBILIZER (DIAGNOSTIC) 2. CHECK KEY WARNING SWITCH CIRCUIT WIRING DIAGRAM: BATTERY M/B No.6 LHD : LHD MODEL : RHD MODEL KEY WARNING SWITCH B141 IMM ECM B141 8 9 10 11 12 5 6 7 8 IM-00006 IM-12...
  • Page 15 Diagnostics Chart for Immobilizer Warning Light IMMOBILIZER (DIAGNOSTIC) Step Check CHECK POWER SUPPLY CIRCUIT. Is the voltage more than 10 V? Go to step 2. Check the harness 1) Disconnect the harness connector from key for open or short warning switch. between key warn- 2) Measure the voltage between key warning ing switch and...
  • Page 16: List Of Diagnostic Trouble Code (Dtc)

    List of Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) 9. List of Diagnostic Trouble Code (DTC) A: LIST Item Contents of diagnosis Index No. <Ref. to IM-15, DTC P1571 REFERENCE CODE Reference Code Incompati- Reference code incompatibility P1571 INCOMPATIBILITY, Diagnostics Procedure with bility between IMM ECM and ECM Diagnostic Trouble Code (DTC).>...
  • Page 17: Diagnostics Procedure With Diagnostic Trouble Code (Dtc)

    Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) 10.Diagnostics Procedure with Diagnostic Trouble Code (DTC) A: DTC P1571 REFERENCE CODE INCOMPATIBILITY DIAGNOSIS: Reference code incompatibility between IMM ECM and ECM Step Check PERFORM TEACHING OPERATION ON IG- Is teaching operation for all Replace the ECM NITION KEY.
  • Page 18: Wiring Diagram

    Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) B: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT) DIAGNOSIS: Communication failure between IMM ECM and ECM WIRING DIAGRAM: IGNITION BATTERY SWITCH SBF-1 SBF-4 F/B No.11 SBF-5 : TURBO MODEL : NON-TURBO MODEL LHD : LHD MODEL RHD : RHD MODEL : LHD TURBO MODEL...
  • Page 19 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) Step Check CHECK POWER SUPPLY CIRCUIT OF IMM Is the voltage more than 10 V? Go to step 2. Check the harness ECM. for open or short 1) Turn the ignition switch to OFF. between IMM 2) Disconnect the harness connector from ECM and fuse.
  • Page 20 Module (ECM).> 3) Perform communication line check. <Ref. to all ignition keys <Ref. to IM-7, COMMUNICATION LINE CHECK, (including the tran- FU(H4DOTC)-50, OPERATION, Subaru Select Monitor.> sponder). Then Engine Control perform teaching Module (ECM).> operation. Refer to <Ref. to the teaching oper- FU(H4DOTC 2.5)-...
  • Page 21 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) C: DTC P1574 KEY COMMUNICATION FAILURE DIAGNOSIS: Failure of IMM ECM to verify key (transponder) ID code Step Check Is the voltage −30 to 30 V? CHECK IMM ECM FUNCTION. Go to step 2. Replace the IMM Insert the key to ignition switch (LOCK posi- (Approx.
  • Page 22 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) D: DTC P0513 INCORRECT IMMOBILIZER KEY DIAGNOSIS: Use of unregistered key in IMM ECM Step Check PERFORM TEACHING OPERATION ON IG- Is teaching operation for all Replace all ignition NITION KEY. keys completed? keys (including the Perform teaching operation on all keys of the...
  • Page 23 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) G: DTC P1570 ANTENNA DIAGNOSIS: Faulty antenna WIRING DIAGRAM: B142 B142 IM-00008 IM-21...
  • Page 24 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) Step Check CHECK ANTENNA CIRCUIT. Is the resistance less than 10 Go to step 2. Replace the Ω? 1) Turn the ignition switch to OFF. antenna. <Ref. to 2) Disconnect the harness antenna connector SL-38, Immobi- from IMM ECM.

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