Subaru 2004 Forester User manual

FUJI HEAVY INDUSTRIES LTD. G8080GE6
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS 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.
FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIAL DI
TRANSFER CASE TC
DRIVE SHAFT SYSTEM DS
ABS ABS
ABS (DIAGNOSTIC) ABS
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING) PS

ABS (DIAGNOSTIC)
ABS
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview...............................................................................6
3. General Description ..................................................................................10
4. Electrical Components Location................................................................12
5. Control Module I/O Signal.........................................................................14
6. Subaru Select Monitor...............................................................................18
7. Read Diagnostic Trouble Code (DTC) ......................................................21
8. Inspection Mode........................................................................................22
9. Clear Memory Mode..................................................................................23
10. ABS Warning Light Illumination Pattern ....................................................24
11. List of Diagnostics Trouble Code (DTC) ...................................................25
12.
Diagnostics Procedure without Diagnostic Trouble Code (DTC) ...................29
13. Diagnostics Procedure with Diagnostic Trouble Code (DTC) ...................94
14. General Diagnostics Table......................................................................174

ABS-2
ABS (DIAGNOSTIC)
Basic Diagnostic Procedure
1. Basic Diagnostic Procedure
A: PROCEDURE
1. WITHOUT SUBARU SELECT MONITOR
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and instal-
lation.
NOTE:
• To check the harness for broken wires or short circuits, shake it while holding it or the connector.
• When the ABS warning light illuminates, read and record DTC indicated by ABS warning light.
Step Check Yes No
1 CHECK PRE-INSPECTION.
1) Ask the customer when and how trouble
occurred using interview checklist. <Ref. to
ABS-6, Check List for Interview.>
2) Before performing diagnosis, inspect the
unit which might influence ABS problem. <Ref.
to ABS-10, INSPECTION, General Descrip-
tion.>
Is the unit that might influence
the ABS problem normal?
Go to step 2. Repair or replace
each unit.
2 CHECK INDICATION OF DTC.
Read the DTC. <Ref. to ABS-21, Read Diag-
nostic Trouble Code (DTC).>
Is the ABS warning light nor-
mal?
Go to step 3. Inspect using diag-
nostic chart for
ABS warning light
failure. <Ref. to
ABS-29, Diagnos-
tics Procedure
without Diagnostic
Trouble Code
(DTC).>
NOTE:
Read the DTC
again after inspect-
ing ABS warning
light. <Ref. to ABS-
21, Read Diagnos-
tic Trouble Code
(DTC).>
3 CHECK DTC.
Record all DTCs.
Is only the start code issued? Go to step 4. Go to step 5.
4 PERFORM THE GENERAL DIAGNOSTICS.
1) Inspect using “General Diagnostics Table”.
<Ref. to ABS-174, General Diagnostics Table.>
2) Perform the clear memory mode. <Ref. to
ABS-23, WITHOUT SUBARU SELECT MONI-
TOR, OPERATION, Clear Memory Mode.>
3) Perform the inspection mode. <Ref. to
ABS-22, Inspection Mode.>
Read the DTC. <Ref. to ABS-21, Read Diag-
nostic Trouble Code (DTC).>
Is only the start code issued? Complete the
diagnosis.
Go to step 5.

ABS-3
ABS (DIAGNOSTIC)
Basic Diagnostic Procedure
5 PERFORM THE DIAGNOSIS.
1) Repair trouble cause.
N
O
TE:
For DTC list, refer to “List of Diagnostics Trou-
ble Code (DTC)”. <Ref. to ABS-25, WITHOUT
SUBARU SELECT MONITOR, LIST, List of Di-
agnostics Trouble Code (DTC).>
2) Perform the clear memory mode. <Ref. to
ABS-23, WITHOUT SUBARU SELECT MONI-
TOR, OPERATION, Clear Memory Mode.>
3) Perform the inspection mode. <Ref. to
ABS-22, Inspection Mode.>
4) Read the DTC. <Ref. to ABS-21, Read
Diagnostic Trouble Code (DTC).>
Is only the start code issued? Complete the
diagnosis.
Repeat the step 5
until only start
code is issued.
Step Check Yes No

ABS-4
ABS (DIAGNOSTIC)
Basic Diagnostic Procedure
2. WITH SUBARU SELECT MONITOR
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and instal-
lation.
NOTE:
• To check the harness for broken wires or short circuits, shake it while holding it or the connector.
• Check list for interview. <Ref. to ABS-6, Check List for Interview.>
Step Check Yes No
1 CHECK PRE-INSPECTION.
1) Ask the customer when and how trouble
occurred using interview checklist. <Ref. to
ABS-6, Check List for Interview.>
2) Before performing diagnosis, inspect the
unit which might influence the ABS problem.
<Ref. to ABS-10, INSPECTION, General
Description.>
Is the unit that might influence
the ABS problem normal?
Go to step 2. Repair or replace
each unit.
2 CHECK INDICATION OF DTC DISPLAY.
1) Turn the ignition switch to OFF.
2) Connect the Subaru Select Monitor to data
link connector.
3) Turn the ignition switch to ON and Subaru
Select Monitor to ON.
N
O
TE:
If the communication function of Subaru Select
Monitor cannot be executed normally, check
communication circuit. <Ref. to ABS-94, COM-
MUNICATION FOR INITIALIZING IMPOSSI-
BLE, Diagnostics Procedure with Diagnostic
Trouble Code (DTC).>
4) Read the DTC. <Ref. to ABS-19, READ
CURRENT DATA, OPERATION, Subaru
Select Monitor.>
5) Record all DTCs and Freeze Frame Data.
Is DTC displayed? Go to step 4. Go to step 3.
3 PERFORM THE GENERAL DIAGNOSTICS.
1) Inspect using a “General Diagnostics
Table”. <Ref. to ABS-174, General Diagnostics
Tabl e. >
2) Perform the clear memory mode. <Ref. to
ABS-19, CLEAR MEMORY MODE, OPERA-
TION, Subaru Select Monitor.>
3) Perform the inspection mode. <Ref. to
ABS-22, Inspection Mode.>
4) Read the DTC. <Ref. to ABS-18, READ
DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.>
Check DTC is not displayed.
Is the ABS warning light turned
off after ignition switch to ON?
Complete the
diagnosis.
Go to step 4.

ABS-5
ABS (DIAGNOSTIC)
Basic Diagnostic Procedure
4 PERFORM THE DIAGNOSIS.
1) Refer to “List of Diagnostics Trouble Code
(DTC)”. <Ref. to ABS-27, WITH SUBARU
SELECT MONITOR, LIST, List of Diagnostics
Trouble Code (DTC).>
2) Repair trouble cause.
3) Perform the clear memory mode. <Ref. to
ABS-19, CLEAR MEMORY MODE, OPERA-
TION, Subaru Select Monitor.>
4) Perform the inspection mode. <Ref. to
ABS-22, Inspection Mode.>
5) Read the DTC. <Ref. to ABS-18, READ
DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.>
Is DTC displayed? Inspect using
“Diagnostics Pro-
cedure with Diag-
nostic Trouble
Code (DTC)”.
<Ref. to ABS-94,
Diagnostics Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
Complete the
diagnosis.
Step Check Yes No

ABS-6
ABS (DIAGNOSTIC)
Check List for Interview
2. Check List for Interview
A: INSPECTION
Check the following items about the vehicle’s state.
1. STATE OF ABS WARNING LIGHT
ABS warning light
comes on.
❏Always
❏Sometimes
❏Only once
❏Not come on
• When / how long does it come on?
Ignition key position ❏LOCK
❏ACC
❏ON (before starting engine)
❏START
❏ON (after Engine starting, engine is running)
❏ON (after Engine starting, engine is at a standstill)
Timing ❏Immediately after turning the ignition switch to ON
❏Immediately after turning the ignition switch to START
❏When accelerating — km/h
—MPH
❏When driving at a constant speed km/h MPH
❏When decelerating — km/h
—MPH
❏When turning to the right Steering angle: deg
Steering time: Sec.
❏When turning to the left Steering angle: deg
Steering time: Sec.
❏When operating other electrical parts
• Parts name:
• Operating condition:

ABS-7
ABS (DIAGNOSTIC)
Check List for Interview
2. STATE OF BRAKE WARNING LIGHT
Brake warning light
comes on.
❏Always
❏Sometimes
❏Only once
❏Not come on
❏When pulling the parking brake lever up.
❏When releasing the parking brake lever down.
• When / how long does it come on?
Ignition key position ❏LOCK
❏ACC
❏ON (before starting engine)
❏START
❏ON (after Engine starting, engine is running)
❏ON (after Engine starting, engine is at a standstill)
Timing ❏Immediately after turning the ignition to ON
❏Immediately after turning the ignition to START
❏When accelerating — km/h
—MPH
❏When driving at a constant speed km/h MPH
❏When decelerating — km/h
—MPH
❏When turning to the right Steering angle: deg
Steering time: Sec.
❏When turning to the left Steering angle: deg
Steering time: Sec.
❏When operating other electrical parts
• Parts name:
• Operating condition:

ABS-8
ABS (DIAGNOSTIC)
Check List for Interview
3. SYMPTOMS
ABS operating condi-
tion
❏Does not move.
❏Operates only when applying an abrupt brake. Vehicle speed: km/h
MPH
• How to step on brake pedal:
a) Operating time: Sec.
b) Operating noise: ❏Occurs. / ❏Does not occur.
• What kind of noise? ❏Knocking
❏Gong gong
❏Bong
❏Buzz
❏Gong gong buzz
❏Others:
c) Reaction force of brake pedal
❏Stick
❏Weak pedal resistance
❏Strong pedal resistance
❏Others:
Behavior of vehicle a) Directional stability cannot be obtained or the steering refuses to work when applying brakes:
❏Ye s / ❏No
• When: ❏When turning to the right
❏When turning to the left
❏When spinning
❏Others:
b) Directional stability cannot be obtained or the steering refuses to work when accelerating:
❏Ye s / ❏No
• When: ❏When turning to the right
❏When turning to the left
❏When spinning
❏Others:
c) Poor brake performance: ❏Ye s / ❏No
• What kind: ❏Long braking/stopping distance
❏Brakes lock or drag
❏Long pedal stroke
❏Pedal sticks.
❏Others:
d) Poor acceleration: ❏Yes / ❏No
• What kind: ❏Not accelerate
❏Engine stalls.
❏Others:
e) Occurrence of vibration: ❏Yes / ❏No
• Where
• What kind:
f) Occurrence of noise: ❏Yes / ❏No
• Where
• What kind:
g) Other troubles occurred: ❏Yes / ❏No
• What kind:

ABS-9
ABS (DIAGNOSTIC)
Check List for Interview
4. CONDITIONS UNDER WHICH TROUBLE OCCURS
Environment a) Weather ❏Fine
❏Cloudy
❏Rainy
❏Snowy
❏Others:
b) Ambient temperature °C (°F)
c) Road ❏Inner city
❏Suburbs
❏Highway
❏Local street
❏Uphill
❏Downhill
❏Paved road
❏Gravel road
❏Muddy road
❏Sandy place
❏Others:
d) Road surface ❏Dried
❏Wet
❏Covered with fresh snow
❏Covered with hardened snow
❏Frozen slope
❏Others:
Condition a) Brakes Deceleration: G
❏Intermittent / ❏Temporary
b) Accelerator Acceleration: G
❏Intermittent / ❏Temporary
c) Vehicle speed km/h MPH
❏Advancing
❏When accelerating
❏When decelerating
❏At low speed
❏When turning
❏Others:
d) Tire inflation pressure Front RH tire: kPa
Front LH tire: kPa
Rear RH tire: kPa
Rear LH tire: kPa
e) Degree of wear Front RH tire:
Front LH tire:
Rear RH tire:
Rear LH tire:
f) Genuine parts are used.: ❏Ye s / ❏No
g) Tire chain is attached: ❏Ye s / ❏No
h) T-type tire is used.: ❏Yes / ❏No
i) Condition of suspension alignment:
j) Loading state:
k) Repair parts are used.: ❏Ye s / ❏No
• Contents:
l) Others: