meter SUBARU FORESTER 2004 Service Owners Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 1094 of 2870
SC(H4SO)-19
STARTING/CHARGING SYSTEM
Generator
E: INSPECTION
1. DIODE
CAUTION:
Never use a mega tester (measuring use for
high voltage) or any other similar measure for
this test; otherwise, the diodes may be dam-
aged.
1) Checking positive diode
Check for continuity between the diode lead and
positive side heat sink. The positive diode is in
good condition if resistance is 1 Ω or less only in the
direction from the diode lead to heat sink.
2) Checking negative diode
Check for continuity between the negative side
heat sink and diode lead. The negative diode is in
good condition if resistance is 1 Ω or less only in the
direction from the heat sink to diode lead.
2. ROTOR
1) Slip ring surface
Inspect the slip rings for contamination or any
roughness of the sliding surface. Repair the slip
ring surface using a lathe or sand paper.
2) Slip ring outer diameter
Measure the slip ring outer diameter. If the slip ring
is worn replace rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
3) Continuity test
Check the resistance between slip rings using cir-
cuit tester.
If the resistance is not within specification, replace
the rotor assembly.
Specified resistance:
Approx. 1.8 — 2.2
Ω
4) Insulation test
Check the continuity between slip ring and rotor
core or shaft. If resistance is 1 Ω or less, the rotor
coil is grounded, and so replace the rotor assem-
bly.
5) Ball bearing (rear side)
Check the rear ball bearing. Replace if it is noisy or
if the rotor does not turn smoothly.
(A) Diode lead
(B) Heat sink (Positive side)
(A) Diode lead
(B) Heat sink (Negative side)
(A)
(B)
SC-00042
(B) (A)
SC-00043
SC-00044
SC-00045
Page 1096 of 2870
SC(H4SO)-21
STARTING/CHARGING SYSTEM
Battery
4. Battery
A: REMOVAL
1) Disconnect the positive (+) cable after discon-
necting the ground (−) cable of battery.
2) Remove the flange nuts from battery rods, and
then take off the battery holder.
3) Remove the battery.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
3.4 N
⋅m (0.35 kgf-m, 2.5 ft-lb)
NOTE:
Clean the battery cable terminals, and then apply
grease to retard formation of corrosion.
Connect the positive (+) cable of battery and then
the ground (−) cable of battery.
C: INSPECTION
WARNING:
Electrolyte has toxicity; be careful handling
the fluid.
Avoid contact with skin, eyes or clothing. Es-
pecially at contact with eyes, blush with water
for 15 minutes and get prompt medical atten-
tion.
Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
Ventilate when charging or using in enclosed
space.
For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a bat-
tery.
Do not let the battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
corrosive acid.
To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle be-
cause a short circuit will be caused.
1. EXTERNAL PARTS:
Check for the existence of dirt or cracks on battery
case, top cover, vent plugs, and terminal posts. If
necessary, clean with water and wipe with a dry
cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.
2. ELECTROLYTE LEVEL:
Check the electrolyte level in each cell. If the level
is below MIN LEVEL, bring the level to MAX LEVEL
by pouring distilled water into the battery cell. Do
not fill beyond MAX LEVEL.
3. SPECIFIC GRAVITY OF ELECTROLYTE:
1) Measure the specific gravity of electrolyte using
a hydrometer and a thermometer.
Specific gravity varies with temperature of electro-
lyte so that it must be corrected at 20°C (68°F) us-
ing the following equation:
S
20 = St+0.0007×(t−20)
S
20: Specific gravity corrected at electrolyte
temperature of 20
°C
St: Measured specific gravity
t: Measured temperature (
°C)
Determine whether or not battery must be
charged, according to corrected specific
gravity.
Standard specific gravity: 1.220 — 1.290 [at
20
°C (68°F)]
2) Measuring the specific gravity of the electrolyte
in battery will disclose the state of charge of bat-
tery. The relation between specific gravity and state
of charge is as shown in the figure.
SC-00053
(1) Specific gravity
(2) Complete charge
(3) Charging condition
(4) Specific gravity and state of charge
1.28
1.26
1.24
1.22
1.20
1.18
1.16
1.14
1.12
100%
(%)75% 50% 22% 0%
SC-00094
[20 C (68 F)](1)
(2) (3)
(4)
Page 1097 of 2870
SC(H4SO)-22
STARTING/CHARGING SYSTEM
Battery
D: MEASUREMENT
WARNING:
Do not bring an open flame close to the bat-
tery at this time.
CAUTION:
Prior to charging, corroded terminals should
be cleaned with a brush and common baking
soda solution.
Be careful since the battery electrolyte over-
flows while charging the battery.
Observe the instructions when handling bat-
tery charger.
Before charging the battery on vehicle, dis-
connect battery ground terminal. Failure to fol-
low this rule may damage alternator’s diodes or
other electrical units.
1. JUDGMENT OF BATTERY IN CHARGED
CONDITION
1) Specific gravity of electrolyte is held at a specific
value in a range from 1.250 to 1.290 for more than
one hour.
2) Voltage per battery cell is held at a specific value
in a range from 2.5 to 2.8 volts for more than one
hour.
2. CHECK HYDROMETER FOR STATE OF
CHARGE
3. NORMAL CHARGING
Charge the battery at current value specified by
manufacturer or at approx. 1/10 of battery’s am-
pere-hour rating.
4. QUICK CHARGING
Quick charging is a method in which the battery is
charged in a short period of time with a relatively
large current by using a quick charger.
Since a large current flow raises electrolyte temper-
ature, the battery is subject to damage if large cur-
rent is used for prolonged time. For this reason, the
quick charging must be carried out within a current
range that will not increase the electrolyte temper-
ature above 40°C (104°F).
It should be also remembered that the quick charg-
ing is a temporary means to bring battery voltage
up to a fair value and, as a rule, a battery should be
charged slowly with a low current.CAUTION:
Observe the items in 3. NORMAL CHARGING.
Never use more than 10 amperes when
charging the battery because that will shorten
battery life.
Hydrometer
indicatorState of charge Required action
Green dot Above 65% Load test
Dark dot Below 65% Charge battery
Clear dot Low electrolyteReplace battery*
(If cranking complaint)
*: Check electrical system before replacement.
Page 1100 of 2870
EN(H4SO)-2
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
1. Basic Diagnostics Procedure
A: PROCEDURE
1. ENGINE
Step Check Yes No
1 CHECK ENGINE START FAILURE.
1) Ask the customer when and how the trou-
ble occurred using the interview check list.
2) Start the engine.Does the engine start? Go to step 2.Inspection using
“Diagnostics for
Engine Starting
Failure”.
Diagnostics for
Engine Starting
Fai lu r e.>
2 CHECK ILLUMINATION OF MALFUNCTION
INDICATOR LIGHT.Does malfunction indicator
light illuminate?Go to step 3.Inspection using
“General Diagnos-
tic Table”.
INSPECTION,
General Diagnos-
tic Table.>
3 CHECK INDICATION OF DTC ON DISPLAY
1) Turn the ignition switch to OFF.
2) Connect the Subaru Select Monitor or the
OBD-II general scan tool to data link connec-
tor.
3) Turn the ignition switch to ON and the Sub-
aru Select Monitor or OBD-II general scan tool
switch to ON.
4) Read the DTC on the Subaru Select Moni-
tor or OBD-II general scan tool.Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC?Record the DTC.
Repair the trouble
cause.
of Diagnostic Trou-
ble Code (DTC).>
Go to step 4.Repair the related
parts.
N
OTE:
If DTC is not shown
on display although
the engine warning
light illuminates, per-
form the diagnostics
of engine warning
light circuit or combi-
nation meter.
Malfunction Indica-
tor Light.>
4 PERFORM THE DIAGNOSIS.
1) Perform the Clear Memory Mode.
2) Perform the Inspection Mode.
tor or OBD-II general scan tool
indicate DTC?Check on “Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC)”
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>Finish the diagno-
sis.
Page 1102 of 2870
EN(H4SO)-4
ENGINE (DIAGNOSTIC)
Check List for Interview
2. Check List for Interview
A: INSPECTION
1. CHECK LIST No. 1
Check the following items when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customer’s name Engine No.
Date of sale Fuel brand
Date of repair
Odometer readingkm
V.I.N.miles
Weather❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Va r i o u s / O t h e r s :
Ambient air temperature°C (°F)
❏ Hot
❏ War m
❏ Cool
❏ Cold
Place❏ Highway
❏ Suburbs
❏ Inner city
❏ Uphill
❏ Downhill
❏ Rough road
❏ Others:
Engine temperature❏ Cold
❏ War ming-up
❏ After warming-up
❏ Any temperature
❏ Others:
Engine speed rpm
Vehicle speed km/h (MPH)
Driving conditions❏ Not affected
❏ At starting
❏ While idling
❏ At racing
❏ While accelerating
❏ While cruising
❏ While decelerating
❏ While turning (RH/LH)
Headlight❏ ON / ❏ OFF Rear defogger❏ ON / ❏ OFF
Blower❏ ON / ❏ OFF Audio❏ ON / ❏ OFF
A/C compressor❏ ON / ❏ OFF Car phone❏ ON / ❏ OFF
Radiator fan❏ ON / ❏ OFF
Fr o nt wi pe r❏ ON / ❏ OFF
Rear wiper❏ ON / ❏ OFF
Page 1104 of 2870
EN(H4SO)-6
ENGINE (DIAGNOSTIC)
General Description
3. General Description
A: CAUTION
1) Airbag system wiring harness is routed near the
ECM, main relay and fuel pump relay.
CAUTION:
All air bag system wiring harnesses and con-
nectors are yellow. Do not use the electrical
test equipment on these circuits.
Be careful not to damage the Airbag system
wiring harness when servicing the ECM, TCM,
main relay and fuel pump relay.
2) Never connect the battery in reverse polarity.
The ECM will be destroyed immediately.
The fuel injector and other part will be damaged.
3) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotive force will be generat-
ed in the generator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn the ignition
switch to OFF.
5) Poor contact has been identified as a primary
cause of this problem. Measure the voltage or re-
sistance of individual sensor or all electrical control
modules using a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the pin more
than 5 mm (0.20 in) into the part.
6) Remove the ECM from the located position after
disconnecting two cables on battery.
Otherwise, the ECM may be damaged.
CAUTION:
When replacing the ECM, be careful not to use
the wrong spec. ECM to avoid any damage on
the fuel injection system.
7) Connectors to each sensor in the engine com-
partment and the harness connectors on the en-
gine side and body side are all designed to be
waterproof. However, it is still necessary to take
care not to allow water to get into the connectors
when washing the vehicle, or when servicing the
vehicle on a rainy day.8) Use ECM mounting stud bolts as the grounding
point to body when measuring voltage and resis-
tance inside the passenger compartment.
9) Use engine ground terminal or engine proper as
the grounding point to body when measuring volt-
age and resistance in the engine compartment.
10) Use TCM mounting stud bolts as the grounding
point to body when measuring voltage and resis-
tance inside the passenger compartment.
11) Every MFI-related part is a precision part. Do
not drop them.
12) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
The antenna must be kept as far apart as pos-
sible from the control unit. (The ECM is located
under the steering column, inside of the instru-
ment panel lower trim panel.)
(A) Stud bolt
(A) Stud bolt
EN-00001
(A)
EN-00153
EN-00154(A)
Page 1105 of 2870
EN(H4SO)-7
ENGINE (DIAGNOSTIC)
General Description
The antenna feeder must be placed as far
apart as possible from the ECM and MFI har-
ness.
Carefully adjust the antenna for correct
matching.
When mounting a large power type radio, pay
special attention to the three items above men-
tioned.
Incorrect installation of the radio may affect
the operation of the ECM.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than five seconds to release pressure in the
fuel system. If engine starts during this operation,
run it until it stops.
14) Problems in the electronic-controlled automatic
transmission may be caused by failure of the en-
gine, the electronic control system, the transmis-
sion proper, or by a combination of these. These
three causes must be distinguished clearly when
performing diagnostics.
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to
complicated, difficult operations. The most impor-
tant thing in diagnostics is to understand the cus-
tomer’s complaint, and distinguish between the
three causes.
16) In AT models, do not continue the stall for more
than five seconds. (from closed throttle, fully open
throttle to stall engine speed.)
17) On the model with ABS, when performing driv-
ing test in jacked-up or lifted-up position, some-
times the warning light may be lit, but this is not a
malfunction of the system. The reason for this is the
speed difference between the front and rear
wheels. After diagnosis of engine control system,
perform the ABS memory clearance procedure of
self-diagnosis function.
B: INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems:
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260
2) Check the condition of the main and other fuses,
and harnesses and connectors. Also check for
proper grounding.
2. ENGINE GROUND
Make sure the engine grounding terminal is proper-
ly connected to the engine.
C: NOTE
1. GENERAL DESCRIPTION
On-board diagnosis (OBD) system detects and
indicates a fault in various inputs and outputs of the
complex electronic control. Malfunction indicator
light in the combination meter indicates occurrence
of a fault or trouble.
Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal driveability.
The OBD system incorporated with the vehicles
within this engine family complies with Section
1968.1, California Code of Regulations (OBD-II
regulation). The OBD system monitors the compo-
nents and the system malfunction listed in Engine
Section which affects on emissions.
When the system decides that a malfunction oc-
curs, malfunction indicator light illuminates. At the
same time of the malfunction indicator light illumi-
nation or blinking, the DTC and a freeze frame en-
gine conditions are stored into on-board computer.
The OBD system stores freeze frame engine
condition data (engine load, engine coolant tem-
perature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it detects
a malfunction first.
If the OBD system detects the various malfunc-
tions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine condi-
tions about the fuel trim or misfire.
When the malfunction does not occur again for
three consecutive driving cycles, malfunction indi-
cator light is turned off, but DTC remains at on-
board computer.
The OBD-II system is capable of communication
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
EN-00153
Page 1106 of 2870
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
Page 1125 of 2870
EN(H4SO)-27
ENGINE (DIAGNOSTIC)
OBD-II General Scan Tool
9. OBD-II General Scan Tool
A: OPERATION
1. HOW TO USE OBD-II GENERAL SCAN
TOOL
1) Prepare a general scan tool (OBD-II general
scan tool) required by SAE J1978.
2) Connect the OBD-II general scan tool to its data
link connector in the lower portion of the instrument
panel (on the driver’s side).3) Using the OBD-II general scan tool, call up the
DTC and freeze frame data.
OBD-II general scan tool functions consist of:
(1) MODE $01: Current powertrain diagnostic
data
(2) MODE $02: Powertrain freeze frame data
(3) MODE $03: Emission-related powertrain
DTC
(4) MODE $04: Clear/Reset emission-related
diagnostic information
Read out data according to repair procedures. (For
detailed operation procedures, refer to the OBD-II
General Scan Tool Operation Manual.)
NOTE:
For details concerning DTCs, refer to the List of Di-
agnostic Trouble Code (DTC).
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)
Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to access generic OBD-II PIDs (MODE
$01).
ME-00325
PID Data Unit of measure
01 Number of emission-related powertrain DTC and malfunction indicator light status ON/OFF
03 Fuel system control status—
04 Calculated engine load value%
05 Engine coolant temperature°C
06 Short term fuel trim%
07 Long term fuel trim%
0B Intake manifold absolute pressure kPa
0C Engine speedrpm
0D Vehicle speedkm/h
0E Ignition timing advance°
10 Air flow rate of manifold absolute pressure sensor g/sec
11 Throttle valve opening angle%
13 Check whether oxygen sensor is installed. —
14Oxygen sensor output voltage and short term fuel trim — bank 1 associated with oxygen sen-
sorV and%
15Oxygen sensor output voltage and short term fuel trim — bank 2 associated with oxygen sen-
sorV and %
1C On-board diagnostic system—
Page 1126 of 2870
EN(H4SO)-28
ENGINE (DIAGNOSTIC)
OBD-II General Scan Tool
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)
Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to access freeze frame data (MODE
$02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODES)
Refer to “Read Diagnostic Trouble Code (DTC)” for information about data denoting emission-related pow-
ertrain DTC.
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to clear or reset emission-related diag-
nostic information (MODE $04).
PID Data Unit of measure
02 DTC that caused CARB required freeze frame data storage —
03 Fuel system control status—
04 Calculated engine load value%
05 Engine coolant temperature°C
06 Short term fuel trim%
07 Long term fuel trim%
0B Intake manifold absolute pressure kPa
0C Engine speedrpm
0D Vehicle speedkm/h