engine SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 2535 of 2870
4AT(H4SO)-76
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
7 CHECK OUTPUT SIGNAL EMITTED FROM
TCM.
1) Return the engine to idling speed and move
select lever to “N” range.
2) Measure the voltage between TCM con-
nector and chassis ground.
Connector & terminal
(B54) No. 7 (+) — Chassis ground (
−):Is the voltage less than 0.5 V? Even if the
POWER indicator
light was blinking,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector or
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.Go to step 10.
8 CHECK OUTPUT SIGNAL EMITTED FROM
TCM USING SUBARU SELECT MONITOR.
1) Connect the connectors to TCM and trans-
mission.
2) Lift-up the vehicle and place rigid rack.
N
OTE:
Raise all wheels off ground.
3) Connect the Subaru Select Monitor to data
link connector.
4) Start the engine and turn Subaru Select
Monitor switch to ON.
5) Start the engine and warm-up the transmis-
sion until ATF temperature is above 80°C
(176°F).
N
OTE:
If ambient temperature is below 0°C (32°F),
drive the vehicle until ATF reaches its operating
temperature.
6) Read the data of lock-up duty solenoid
using Subaru Select Monitor.
Lock-up duty solenoid is indicated in “%”.
7) Move the selector lever to “D” range and
slowly increase vehicle speed to 60 km/h (37
MPH). Wheels will lock-up.
N
OTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diag-
nosis is finished, perform the ABS memory
clearance procedure of on-board diagnostics
system.
9 CHECK OUTPUT SIGNAL EMITTED FROM
TCM USING SUBARU SELECT MONITOR.
1) Return the engine to idling speed and move
selector lever to “N” range.
N
OTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diag-
nosis is finished, perform the ABS memory
clearance procedure of on-board diagnostics
system.
2) Read the data of lock-up duty solenoid
using Subaru Select Monitor.Is the value 5%? Even if the
POWER indicator
light was blinking,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector or
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.Go to step 10. Step Check Yes No
Page 2538 of 2870
4AT(H4SO)-79
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
2 CHECK HARNESS CONNECTOR BETWEEN
TCM AND TRANSMISSION.
Measure the resistance harness connector
between TCM and chassis ground.
Connector & terminal
(B54) No. 6 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 3.Repair the short
circuit in harness
between TCM and
transmission con-
nector.
3 CHECK TRANSFER DUTY SOLENOID.
Measure the resistance between transmission
connector and transmission terminals.
Connector & terminal
(T4) No. 6 — No. 16:Is the resistance 10 — 17 Ω? Go to step 4.Go to step 10.
4 PREPARE SUBARU SELECT MONITOR.Do you have a Subaru Select
Monitor?Go to step 7.Go to step 5.
5 CHECK OUTPUT SIGNAL EMITTED FROM
TCM.
1) Connect the connectors to TCM and trans-
mission.
2) Turn the ignition switch to ON (engine OFF).
3) Move the select lever to “P” range.
4) Throttle is fully closed.
5) Measure the voltage between TCM con-
nector and chassis ground.
Connector & terminal
(B54) No. 6 (+) — Chassis ground (
−):Is the voltage more than 8.5 V? Go to step 6.Go to step 9.
6 CHECK OUTPUT SIGNAL EMITTED FROM
TCM.
1) Move the select lever to “D” range.
2) Measure the voltage between TCM con-
nector and chassis ground.
Connector & terminal
(B54) No. 6 (+) — Chassis ground (
−):Is the voltage 3.0 — 6.0 V? Even if the
POWER indicator
light was blinking,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector or
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.Go to step 9.
7 CHECK OUTPUT SIGNAL EMITTED FROM
TCM USING SUBARU SELECT MONITOR.
1) Connect the connectors to TCM and trans-
mission.
2) Connect the Subaru Select Monitor to data
link connector.
3) Turn the ignition switch to ON (engine OFF)
and turn Subaru Select Monitor switch to ON.
4) Move the select lever to “D” range with throt-
tle fully open (vehicle speed 0 km/h (0 MPH)).
5) Read data of transfer duty solenoid using
Subaru Select Monitor.
Transfer duty solenoid is indicated in “%”.Is the value 80 — 95%? Go to step 8.Go to step 9. Step Check Yes No
Page 2541 of 2870
4AT(H4SO)-82
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK HARNESS CONNECTOR BETWEEN
TCM AND TRANSMISSION.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from TCM and
transmission.
3) Measure the resistance of harness
between TCM and transmission connector.
Connector & terminal
(B55) No. 24 — (B11) No. 19:Is the resistance less than 1
Ω?Go to step 2.Repair the open
circuit in harness
between TCM and
transmission con-
nector.
2 CHECK HARNESS CONNECTOR BETWEEN
TCM AND TRANSMISSION.
Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
(B54) No. 19 — (B11) No. 20:Is the resistance less than 1
Ω?Go to step 3.Repair the open cir-
cuit in harness
between TCM and
transmission, and
poor contact in cou-
pling connector.
3 CHECK HARNESS CONNECTOR BETWEEN
TCM AND TRANSMISSION.
Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
(B55) No. 24 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 4.Repair the short
circuit in harness
between TCM and
transmission con-
nector.
4 CHECK HARNESS CONNECTOR BETWEEN
TCM AND TRANSMISSION.
Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
(B54) No. 19 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 5.Repair the short
circuit in harness
between TCM and
transmission con-
nector.
5 CHECK REAR VEHICLE SPEED SENSOR.
Measure the resistance between transmission
connector receptacle’s terminals.
Connector & terminal
(T4) No. 19 — No. 20:Is the resistance 450 — 650
Ω?Go to step 6.Replace the rear
vehicle speed sen-
sor.
Speed Sensor.>
6 PREPARE OSCILLOSCOPE.Do you have an oscilloscope? Go to step 10.Go to step 7.
7 PREPARE SUBARU SELECT MONITOR.Do you have a Subaru Select
Monitor?Go to step 9.Go to step 8.
8 CHECK INPUT SIGNAL FOR TCM.
1) Connect the connectors to TCM and trans-
mission.
2) Lift-up or raise the vehicle and place rigid
rack.
N
OTE:
Raise all wheels off floor.
3) Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
N
OTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diag-
nosis is finished, perform the ABS memory
clearance procedure of on-board diagnostics
system.
4) Measure the voltage between TCM con-
nector terminals.
Connector & terminal
(B55) No. 24 (+) — (B54) No. 19 (
−):Is the voltage more than AC 1
V?Even if the
POWER indicator
light was blinking,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector or
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.Go to step 11.
Page 2542 of 2870
4AT(H4SO)-83
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
9 CHECK INPUT SIGNAL FOR TCM USING
SUBARU SELECT MONITOR.
1) Connect the connectors to TCM and trans-
mission.
2) Connect the Subaru Select Monitor to data
link connector.
3) Lift-up or raise the vehicle and place rigid
rack.
N
OTE:
Raise all wheels off floor.
4) Turn the ignition switch to ON and turn Sub-
aru Select Monitor switch to ON.
5) Start the engine.
6) Read the data of vehicle speed using Sub-
aru Select Monitor.
Compare the speedometer with Subaru
Select Monitor indications.
Vehicle speed is indicated in “km/h” or
“MPH”.
7) Slowly increase the vehicle speed to 60 km/
h (37 MPH).
N
OTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diag-
nosis is finished, perform the ABS memory
clearance procedure of on-board diagnostics
system.
tion increase as the Subaru
Select Monitor data increases?Even if the
POWER indicator
light was blinking,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector or
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.Go to step 11.
10 CHECK INPUT SIGNAL FOR TCM USING
OSCILLOSCOPE.
1) Connect the connectors to TCM and trans-
mission.
2) Lift-up or raise the vehicle and place rigid
rack.
NOTE:
Raise all wheels off floor.
3) Set the oscilloscope to TCM connector ter-
minals.
Connector & terminal
Positive probe; (B55) No. 24
Earth lead; (B54) No. 19
4) Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diag-
nosis is finished, perform the ABS memory
clearance procedure of on-board diagnostics
system.
5) Measure the signal voltage indicated on
oscilloscope.Is the signal voltage more than
AC 1 V?Even if the
POWER indicator
light was blinking,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector or
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.Go to step 11.
11 CHECK POOR CONTACT.Is there poor contact in rear
vehicle speed sensor circuit?Repair the poor
contact.Replace the TCM.
trol Module
(TCM).> Step Check Yes No
Page 2549 of 2870
4AT(H4SO)-90
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
4 CHECK KICK-DOWN SWITCH.
Measure the resistance for kick-down switch
when releasing the accelerator pedal.
Te r m i n a l s
No. 1 — No. 2:Is the resistance more than 1
MΩ?Go to step 5.Replace the kick-
down switch.
Accelerator
Pedal.>
5 CHECK HARNESS CONNECTOR BETWEEN
TCM AND KICK-DOWN SWITCH.
1) Turn the ignition switch to OFF.
2) Disconnect the connectors from kick-down
switch.
3) Measure the resistance of harness connec-
tor between TCM and kick-down switch.
Connector & terminal
(B55) No. 11 — (B129) No. 2:Is the resistance less than 1
Ω?Go to step 6.Repair the open
circuit in harness
between TCM and
kick-down switch.
6 CHECK HARNESS CONNECTOR BETWEEN
TCM AND KICK-DOWN SWITCH.
Measure the resistance of harness connector
between TCM and chassis ground.
Connector & terminal
(B55) No. 11 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 7.Repair the short
circuit in harness
between TCM and
chassis ground.
7 CHECK INPUT SIGNAL FOR TCM.
1) Turn the ignition switch to OFF.
2) Connect the connector to kick-down switch.
3) Turn the ignition switch to ON (engine OFF).
4) Measure the signal voltage for TCM when
depressing the accelerator pedal.
Connector & terminal
(B55) No. 11 (+) — Chassis ground (
−):Is the voltage less than 1 V? Go to step 8.Go to step 9.
8 CHECK INPUT SIGNAL FOR TCM.
Measure the signal voltage for TCM when
releasing the accelerator pedal.
Connector & terminal
(B55) No. 11 (+) — Chassis ground (
−):Is the voltage more than 6.5 V? A temporary poor
contact of the con-
nector and har-
ness may be the
cause. Repair the
harness and con-
nector in TCM.Go to step 9.
9 CHECK POOR CONTACT.Is there poor contact? Repair the poor
contact.Replace the TCM.
trol Module
(TCM).> Step Check Yes No
Page 2553 of 2870
4AT(H4SO)-94
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
9 CHECK INPUT SIGNAL FOR TCM.
1) Connect the connectors to TCM and
POWER switch.
2) Turn the ignition switch to ON (engine OFF).
3) Measure the signal voltage for TCM while
turning POWER switch to OFF.
Connector & terminal
(B55) No. 23 (+) — Chassis ground (–):Is the voltage more than 10 V? Go to step 10.Replace the TCM.
trol Module
(TCM).>
10 CHECK INPUT SIGNAL FOR TCM.
Measure the signal voltage for TCM while turn-
ing POWER switch to ON.
Connector & terminal
(B55) No. 23 (+) — Chassis ground (–):Is the voltage less than 1 V? Go to step 11.Replace the TCM.
trol Module
(TCM).>
11 CHECK POOR CONTACT.Is there poor contact in
POWER switch circuit?Repair the poor
contact.A temporary poor
contact of the con-
nector or harness
or connector in
POWER switch cir-
cuit. Step Check Yes No
Page 2554 of 2870
4AT(H4SO)-95
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
G: CHECK INHIBITOR SWITCH
DETECTING CONDITION:
The input signal circuit of inhibitor switch is open or shorted.
TROUBLE SYMPTOM:
Shift characteristics are erroneous.
Engine brake is not effected when selector lever is in “3” range.
Engine brake is not effected when selector lever is in “2” range.
Engine brake is not effected when selector lever is in “1” range.
Page 2568 of 2870
4AT(H4SO)-109
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
9 CHECK HARNESS CONNECTOR BETWEEN
TCM AND HOLD SWITCH.
Measure the resistance of harness connector
between TCM and chassis ground to make
sure that circuit does not short.
Connector & terminal
(B55) No. 16 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 10.Repair the short
circuit in harness
between TCM and
HOLD switch con-
nector.
10 CHECK INPUT SIGNAL FOR TCM.
1) Connect the connectors to TCM and HOLD
switch.
2) Turn the ignition switch to ON (engine OFF).
3) Measure the signal voltage for TCM while
turning HOLD switch to OFF.
Connector & terminal
(B55) No. 16 (+) — Chassis ground (–):Is the voltage more than 8 V? Go to step 11.Replace the TCM.
trol Module
(TCM).>
11 CHECK INPUT SIGNAL FOR TCM.
Measure the signal voltage for TCM while turn-
ing HOLD switch to ON.
Connector & terminal
(B55) No. 16 (+) — Chassis ground (–):Is the voltage less than 1 V? Go to step 12.Replace the TCM.
trol Module
(TCM).>
12 CHECK POOR CONTACT.Is there poor contact in HOLD
switch circuit?Repair the poor
contact.A temporary poor
contact of the con-
nector or harness or
connector in HOLD
switch circuit. Step Check Yes No
Page 2569 of 2870
4AT(H4SO)-110
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
15.Symptom Related Diagnostic
A: INSPECTION
Symptom Problem parts
Starter does not rotate when select lever is in “P” or “N” range;
starter rotates when select lever is in “R”, “D”, “3” or “2” range. Inhibitor switch
Select cable
Select lever
Starter motor and harness
Abnormal noise when select lever is in “P” or “N” range. Strainer
Transfer duty solenoid
Oil pump
Drive plate
ATF level too high or too low
Hissing noise occurs during standing start. Strainer
ATF level too high or too low
Noise occurs while driving in “D1”. Final gear
Planetary gear
Reduction gear
Differential gear oil level too high or too low Noise occurs while driving in “D2”.
Noise occurs while driving in “D3”. Final gear
Low & reverse brake
Reduction gear
Differential gear oil level too high or too low
Noise occurs while driving in “D4”. Final gear
Low & reverse brake
Planetary gear
Reduction gear
Differential gear oil level too high or too low
Engine stalls while shifting from “1” range to another. Control valve
Lock-up damper
Engine performance
Input shaft
Vehicle moves when select lever is in “N” range. Low clutch
Shock occurs when select lever is moved from “N” to “D” range.TCM
Harness
Control valve
ATF deterioration
Excessive time lag occurs when select lever is moved from “N”
to “D” range. Control valve
Low clutch
Line pressure duty solenoid
Seal ring
Front gasket transmission case
Shock occurs when select lever is moved from “N” to “R” range.TCM
Harness
Control valve
ATF deterioration
Excessive time lag occurs when select lever is moved from “N”
to “R” range. Control valve
Low & reverse clutch
Reverse clutch
Line pressure duty solenoid
Seal ring
Front gasket transmission case
Vehicle does not start in any shift range (engine stalls). Parking brake mechanism
Planetary gear
Page 2570 of 2870
4AT(H4SO)-111
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
Vehicle does not start in any shift range (engine revving up). Strainer
Line pressure duty solenoid
Control valve
Drive pinion
Hypoid gear
Axle shaft
Differential gear
Oil pump
Input shaft
Output shaft
Planetary gear
Drive plate
ATF level too low
Front gasket transmission case
Vehicle does not start in “R” range only (engine revving up). Select cable
Select lever
Control valve
Low & reverse clutch
Reverse clutch
Vehicle does not start in “R” range only (engine stalls). Low clutch
2-4 brake
Planetary gear
Parking brake mechanism
Vehicle does not start in “D”, “3” range only (engine revving up). Low clutch
One-way clutch
Vehicle does not start in “D”, “3” or “2” range only (engine rev-
ving up). Low clutch
Vehicle does not start in “D”, “3” or “2” range only (engine stalls). Reverse clutch
Vehicle starts in “R” range only (engine revving up). Control valve
Acceleration during standing starts is poor (high stall rpm). Control valve
Low clutch
Reverse clutch
ATF level too low
Front gasket transmission case
Differential gear oil level too high or too low
Acceleration during standing starts is poor (low stall rpm). Oil pump
Torque converter one-way clutch
Engine performance
Acceleration is poor when select lever is in “D”, “3” or “2” range
(normal stall rpm).TCM
Control valve
High clutch
2-4 brake
Planetary gear
Acceleration is poor when select lever is in “R” (normal stall rpm). Control valve
High clutch
2-4 brake
Planetary gear
No shift occurs from 1st to 2nd gear.TCM
Rear vehicle speed sensor
Front vehicle speed sensor
Throttle position sensor
Shift solenoid 1
Control valve
2-4 brake
No shift occurs from 2nd to 3rd gear.TCM
Control valve
High clutch
Shift solenoid 2 Symptom Problem parts