Subaru 2004 Forester Manuale utente

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.

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.

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:

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