2004 SUBARU FORESTER brake sensor

CC(H4SO)-8
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Cruise Control Module I/O Signal
B: WIRING DIAGRAM

Brake switch/Clutch switch
(MT model)16 Leave clutch pedal released (MT model), while cruise control main switch is
turned ON.
Then check that;
 Battery voltage is present when brake pedal is released.
 “0” volt is present when brake pedal is depressed.
Additionally only in MT model, keep the cruise control main switch to ON and
leave brake pedal released.
Then check that;
 Battery voltage is present when clutch pedal is released.
 “0” volt is present when clutch pedal is depressed.
Data link connector 17 —
Data link connector 18 —
Vehicle speed sensor (MT
model)
TCM (AT model)19 Lift-up the vehicle until all four wheels are raised off ground, and then rotate any
wheel manually.
Approx. “5” and “0” volt pulse signals are alternately input to cruise control mod-
ule.
Stop light switch 20 Turn ignition switch to OFF.
Then check that;
 Battery voltage is present when brake pedal is depressed.
 “0” volt is present when brake pedal is released.
NOTE:
Voltage at terminals 5, 7, 13 and 14 cannot be checked unless vehicle is driving by cruise control operation.Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)

CC(H4SO)-11
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Symptom
6. Diagnostic Procedure with Symptom
A: SYMPTOM CHART
Symptom Repair area Reference
1Cruise control main switch is
not turned ON. (1) Check the power supply. nostic Procedure with Symptom.>
(2) Check the cruise control
main switch. MAIN SWITCH, Diagnostic Procedure with Symptom.>
2Cruise indicator light does not
illuminate.Check the cruise indicator
light. LIGHT, Diagnostic Procedure with Symptom.>
3Cruise control cannot be set. (1) Check the SET/COAST
switch. COMMAND SWITCH, Diagnostic Procedure with Symp-
tom.>
(2) Check the stop light switch
and brake switch. AND BRAKE SWITCH, Diagnostic Procedure with Symp-
tom.>
(3) Check the clutch switch
(MT model). MODEL), Diagnostic Procedure with Symptom.>
(4) Check the inhibitor switch
(AT model). (AT MODEL), Diagnostic Procedure with Symptom.>
(5) Check the vehicle speed
sensor. SOR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
(6) Check the motor drive
system. MOTOR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
(7) Check the motor clutch
drive system. CLUTCH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
4Vehicle speed is not held
within set speed ±3 km/h (±2
MPH). (1) Check the vehicle speed
sensor. SOR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
(2) Check the motor drive
system. MOTOR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
(3) Check the motor clutch
drive system. CLUTCH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
5Vehicle speed does not
increase or does not return to
set speed after RESUME/
ACCEL switch has been
pressed.(1) Check the RESUME/
AC CEL switch. COMMAND SWITCH, Diagnostic Procedure with Symp-
tom.>
(2) Check the motor drive
system. MOTOR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
(3) Check the motor clutch
drive system. CLUTCH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
6Vehicle speed does not
decrease after SET/COAST
switch has been pressed. (1) Check the SET/COAST
switch. COMMAND SWITCH, Diagnostic Procedure with Symp-
tom.>
(2) Check the motor drive
system. MOTOR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
(3) Check the motor clutch
drive system. CLUTCH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>

CC(H4DOTC 2.5)-10
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Symptom
6. Diagnostic Procedure with Symptom
A: SYMPTOM CHART
Symptom Repair area Reference
1Cruise control main switch is
not turned to ON. (Cruise
indicator light does not illumi-
nate)(1) Check the cruise indicator
light. TOR LIGHT, Diagnostic Procedure with Symptom.>
(2) Check the cruise control
command switch. CRUISE CONTROL COMMAND SWITCH, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
2 Cruise control cannot be set. (1) Check the cruise control
command switch CRUISE CONTROL COMMAND SWITCH, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
(2) Check the stop light switch
and brake switch. LIGHT SWITCH AND BRAKE SWITCH, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
(3) Check the clutch switch. SWITCH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
(4) Check the neutral switch. TION SWITCH, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
(5) Check the vehicle speed
sensor. SPEED SENSOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
3Vehicle speed is not held
within set speed ±3 km/h (±2
MPH). Check the vehicle speed sen-
sor. SPEED SENSOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
4Vehicle speed does not
increase or does not return to
set speed after RESUME/
ACCEL switch has been
pressed.Check the RESUME/ACCEL
switch. CRUISE CONTROL COMMAND SWITCH, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
5Vehicle speed does not
decrease after SET/COAST
switch has been pressed. Check the SET/COAST
switch. CRUISE CONTROL COMMAND SWITCH, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
6Cruise control is not released
after CANCEL switch has
been pressed.Check the CANCEL switch. CRUISE CONTROL COMMAND SWITCH, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
7Cruise control is not released
after the brake pedal has
been depressed. Check the stop light switch
and brake switch. LIGHT SWITCH AND BRAKE SWITCH, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
8Cruise control is not released
after the clutch pedal has
been depressed.Check the clutch switch. SWITCH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
9Cruise control is not released
after shifting to neutral posi-
tion.Check the neutral switch. TION SWITCH, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>

CC(H4DOTC 2.5)-14
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
List of Diagnostic Trouble Code (DTC)
21 Cruise control switch is
abnormal when the igni-
tion switch is turned to ON.Each switch of cruise control command switch has
already been ON when the ignition switch is turned to
ON.This DTC is indicated
without operating the main
switch. CC(H4DOTC 2.5)-16,
DTC 11, 15, 21 AND 24
CRUISE CONTROL
COMMAND SWITCH,
Diagnostic Procedure with
Diagnostic Trouble Code
(DTC).>
22 Vehicle speed variation is
abnormal.Abnormality of vehicle speed variation is detected. 2.5)-26, DTC 22 AND 32
VEHICLE SPEED SEN-
SOR, Diagnostic Proce-
dure with Diagnostic
Trouble Code (DTC).>
23 Engine-related sensor is
abnormal.Abnormality related to engine is detected. 2.5)-2, Basic Diagnostic
Procedure.>
24 Cruise control-related
switch is abnormal.Abnormality of command switch is detected. (Open cir-
cuit is detected when continuing to be ON for an
extremely long time [approx. two minutes].)This DTC is indicated with
normal operation. CC(H4DOTC 2.5)-16,
DTC 11, 15, 21 AND 24
CRUISE CONTROL
COMMAND SWITCH,
Diagnostic Procedure with
Diagnostic Trouble Code
(DTC).>
25 Brake switch input circuit
is abnormal.Abnormality of brake switch input circuit in ECM is
detected. 2.5)-18, DTC 12 AND 25
STOP LIGHT SWITCH
AND BRAKE SWITCH,
Diagnostic Procedure with
Diagnostic Trouble Code
(DTC).>
26 Engine speed signal.  Abnormal increase of engine speed is detected.
 Gear is shifted to neutral, 1st or reverse position.Cruise with more than 2nd
shift position.
32 Out of vehicle speed range
of cruise control operation. Vehicle speed becomes under the control limit during
cruise driving.
 Set operation is conducted out of vehicle speed range
for setting
 RESUME operation is conducted without vehicle
speed memory.This DTC is also indicated
when increasing the
speed to the cruise set
available vehicle speed
and conducting the set
operation again. CC(H4DOTC 2.5)-26,
DTC 22 AND 32 VEHICLE
SPEED SENSOR, Diag-
nostic Procedure with
Diagnostic Trouble Code
(DTC).>
33 Prohibition of WAIT after
acceleration operation.Vehicle speed becomes over the control limit during
cruise driving.This DTC is indicated
when running at the high
speed which is not suit-
able for cruise control. In
this case, conduct the
cruise set operation again
after decreasing the
speed to the cruise set
available vehicle speed. DTC Item Contents of diagnosis Reference

RM-5
RECOMMENDED MATERIAL
Recommended Materials
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
5. COOLANT
Use genuine coolant to protect the engine.
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any air compressor oil except for ZXL200PG.
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
SAE viscosity No. and applicable temperature SAE J300
Manual transmission oil, front differential oil and rear differential oil
Fluid Recommended Alternative Remarks
Automatic transmission fluid DEXRON III — —
Power steering fluid DEXRON III — —
Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
Coolant Recommended Item number Alternative
Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water — Tap water (Soft water)
Air conditioner Recommended Item number Alternative
Refrigerant HFC134a — None
Compressor oil ZXL200PG — None
Grease Application point Recommended Item number Alternative
Supplementary lubricants  Oxygen sensor
 Bolts, etc.SUBARU CRC 004301003 —
RM-00004 (F)–22 –4 14 50 68 86 104 (C)–30 –20 –100
10 20 30 40
85W
75W-9080W90
32

FU(H4SO)-15
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(7) Place the power steering pump on the right
side wheel apron.
8) Disconnect the spark plug cords from the spark
plugs.
9) Disconnect the PCV hose from the intake mani-
fold.
10) Disconnect the engine coolant hose (A) from
the throttle body.
11) Disconnect the brake booster hose.12) Remove the air cleaner case stay RH and en-
gine harness bracket, and disconnect the engine
harness connectors from the bulkhead harness
connectors.
13) Disconnect the connectors from the engine
coolant temperature sensor.
14) Disconnect the knock sensor connector.
15) Disconnect the connector from the crankshaft
position sensor.
FU-00021
FU-00141
FU-00361
(A)(A)
FU-00143
FU-00258
FU-00145
FU-00062
FU-00056

CO(H4SO)-43
COOLING
Engine Cooling System Trouble in General
12.Engine Cooling System Trouble in General
A: INSPECTION
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish the engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace the timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair the ignition control system.

nostics Procedure.>
h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace the engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair the fuel injection system.

nostics Procedure.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Defective thermostat Replace.
p. Malfunction of radiator fanInspect the radiator fan relay, engine coolant tempera-
ture sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover the radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten the cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective water pump bearing Replace the water pump.
d. Defective water pump mechanical seal Replace the water pump.

EN(H4SO)-8
ENGINE (DIAGNOSTIC)
General Description
 The OBD-II diagnostics procedure is different
from the usual diagnosis procedure. When trouble-
shooting the OBD-II models, connect Subaru Se-
lect Monitor or the OBD-II general scan tool to the
vehicle.
2. ENGINE AND EMISSION CONTROL SYS-
TEM
 MFI system is a system that supplies the opti-
mum air-fuel mixture to the engine for all the vari-
ous operating conditions through the use of the
latest electronic technology.
With this system fuel, which is pressurized at a con-
stant pressure, is injected into the intake air pas-
sage of the cylinder head. The injection quantity of
fuel is controlled by an intermittent injection system
where the electro-magnetic injection valve (fuel in-
jector) opens only for a short period of time, de-
pending on the quantity of air required for one cycle
of operation. In actual operation, the injection quan-
tity is determined by the duration of an electric sig-
nal applied to the fuel injector and this permits
simple, yet highly precise metering of the fuel.
 Further, all the operating conditions of the engine
are converted into electric signals, and this results
in additional features of the system, such as large
improved adaptability, easier addition of compen-
sating element, etc.The MFI system also has the following features:
 Reduced emission of harmful exhaust gases.
 Reduced in fuel consumption.
 Increased engine output.
 Superior acceleration and deceleration.
 Excellent engine start and warm-up perfor-
mance by the correction of engine coolant tem-
perature and intake air temperature.3. AUTOMATIC TRANSMISSION AND
ELECTRONIC-HYDRAULIC CONTROL SYS-
TEM
The electronic-hydraulic control system consists of
various sensors and switches, TCM and the hy-
draulic controller including solenoid valves. The
system controls the transmission body including
shift control, lock-up control, overrunning clutch
control, line pressure control and shift timing con-
trol. It also controls the AWD transfer clutch. In oth-
er words, the system detects various operating
conditions from various input signals and sends
output signals to shift solenoids 1, 2 and low clutch
timing solenoid and 2-4 brake timing solenoid, line
pressure duty solenoid, lock-up duty solenoid,
transfer duty solenoid and 2-4 brake duty solenoid
(a total of eight solenoids).
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical system.
22771AA030 SUBARU SELECT
MONITOR KITTroubleshooting for electrical system.
 English: 22771AA030 (Without printer)
 German: 22771AA070 (Without printer)
 French: 22771AA080 (Without printer)
 Spanish: 22771AA090 (Without printer)
ST24082AA230
ST22771AA030