lock 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 1137 of 2870
EN(H4SO)-39
ENGINE (DIAGNOSTIC)
Inspection Mode
1. PREPARATION FOR THE INSPECTION
MODE
1) Check battery voltage is more than 12 V and fuel
remains half [20 — 402 (5.3 — 10.6 US gal, 4.4 —
8.8 Imp gal)].
2) Lift-up the vehicle using a garage jack and place
it on rigid racks or drive the vehicle onto free rollers.
WARNING:
Before lifting-up the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a rig-
id rack.
Secure a rope or wire to the front or rear tow-
ing hooks to prevent the lateral runout of front
wheels.
Do not abruptly depress/release clutch pedal
or accelerator pedal during works even when
the engine is operating at low speeds since this
may cause vehicle to jump off free rollers.
In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the rigid racks
and the vehicle.
Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
2. SUBARU SELECT MONITOR
1) After clearing the memory, check for any remain-
ing unresolved trouble data.
2) Idle the engine.
3) Prepare the Subaru Select Monitor kit.
scription.>
4) Connect the diagnosis cable to Subaru Select
Monitor.
5) Insert the cartridge to Subaru Select Monitor.
6) Connect the test mode connector (A) located at
the lower portion of instrument panel (on the driv-
er’s side).
(A) Rigid rack
(B) Free rollers
EN-00041
(A)
(B)
EN-00038
EN-00039
EN-00238
(A)
Page 1173 of 2870
EN(H4SO)-75
ENGINE (DIAGNOSTIC)
List of Diagnostic Trouble Code (DTC)
P0720 AT Vehicle Speed Sensor Circuit
Malfunction
P0726 Engine Speed Input Circuit Malfunc-
tion
P0731 Gear 1 Incorrect Ratio
P0732 Gear 2 Incorrect Ratio
P0733 Gear 3 Incorrect Ratio
P0734 Gear 4 Incorrect Ratio
P0741 Torque Converter Clutch Circuit Per-
formance or Stuck Off
Diagnostic Trouble Code (DTC).>
P0743 Torque Converter Clutch Circuit Elec-
trical
P0748 Pressure Control Solenoid “A” Elec-
trical
P0753 Shift Solenoid “A” Electrical
P0758 Shift Solenoid “B” Electrical
P0771 Low clutch timing solenoid
P0778 Pressure Control Solenoid “B” Elec-
trical
P0785 Shift/Timing Solenoid
P0851 Neutral Switch Input Circuit Low
(MT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0852 Neutral Switch Input Circuit High
P0864 TCM Communication Circuit Range/
Pe r fo r ma nc e
Code (DTC).>
P0865 TCM Communication Circuit Low
P0866 TCM Communication Circuit Low
P1110 Atmospheric Pressure Sensor Circuit
Malfunction (Low Input)
Diagnostic Trouble Code (DTC).>
P1111 Atmospheric Pressure Sensor Circuit
Malfunction (High Input)
Diagnostic Trouble Code (DTC).>
P1134 A/F Sensor Micro-Computer Problem
P1137 O
2 Sensor Circuit (Lambda= 1)
(Bank 1 Sensor 1)
(DTC).>
P1492 EGR Valve Signal #1 Circuit Malfunc-
tion (Low Input)
ble Code (DTC).> DTC Item NOTE
Page 1242 of 2870
EN(H4SO)-144
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
6 CHECK POWER SUPPLY LINE.
1) Turn the ignition switch to ON.
2) Measure the voltage between fuel injector
and engine ground on faulty cylinders.
Connector & terminal
#1 (E5) No. 2 (+) — Engine ground (
−):
#2 (E16) No. 2 (+) — Engine ground (
−):
#3 (E6) No. 2 (+) — Engine ground (
−):
#4 (E17) No. 2 (+) — Engine ground (
−):Is the voltage more than 10 V? Repair poor con-
tact in all connec-
tors in fuel injector
circuit.Repair harness
and connector.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
main relay and fuel
injector connector
on faulty cylinders
Poor contact in
coupling connector
Poor contact in
main relay connec-
tor
Poor contact in
fuel injector con-
nector on faulty
cylinders
7 CHECK HARNESS BETWEEN FUEL INJEC-
TOR AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from fuel injector
on faulty cylinder.
3) Turn the ignition switch to ON.
4) Measure the voltage between ECM con-
nector and chassis ground on faulty cylinders.
Connector & terminal
#1 (B134) No. 34 (+) — Chassis ground (
−):
#2 (B134) No. 23 (+) — Chassis ground (
−):
#3 (B134) No. 22 (+) — Chassis ground (
−):
#4 (B134) No. 8 (+) — Chassis ground (
−):Is the voltage more than 10 V? Repair battery
short circuit in har-
ness between
ECM and fuel
injector. After
repair, replace the
ECM.
Engine Control
Module (ECM).>Go to step 8.
8 CHECK FUEL INJECTOR.
1) Turn the ignition switch to OFF.
2) Measure the resistance between fuel injec-
tor terminals on faulty cylinder.
Te r m i n a l s
No. 1 — No. 2:Is the resistance less than 1
Ω?Replace the faulty
fuel injector
Fuel Injector.> and
ECM.
Engine Control
Module (ECM).>Go to step 9.
9 CHECK INSTALLATION OF CAMSHAFT PO-
SITION SENSOR/CRANKSHAFT POSITION
SENSOR.Is the installation of camshaft
position sensor or crankshaft
position sensor loosened?Tighten camshaft
position sensor or
crankshaft posi-
tion sensor.Go to step 10.
10 CHECK CRANK SPROCKET.
Remove the timing belt cover.Is the crank sprocket rusted or
does it have broken teeth?Replace the crank
sprocket.
Crank Sprocket.>Go to step 11.
11 CHECK INSTALLATION CONDITION OF
TIMING BELT.
Turn the crankshaft using ST, and align align-
ment mark on crank sprocket with alignment
mark on cylinder block.
ST 499987500 CRANKSHAFT SOCKETIs the timing belt dislocated
from its proper position?Repair installation
condition of timing
belt.
Timing Belt.>Go to step 12.
12 CHECK FUEL LEVEL.Is the fuel meter indication
higher than the “Lower” level?Go to step 13.Replenish fuel so
fuel meter indica-
tion is higher than
the “Lower” level.
After replenishing
fuel, Go to step 13. Step Check Yes No
Page 1253 of 2870
EN(H4SO)-155
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK ANY OTHER DTC ON DISPLAY.Is any other DTC displayed? Inspect the DTC
using “List of Diag-
nostic Trouble
Code (DTC)”.
of Diagnostic Trou-
ble Code (DTC).>Go to step 2.
2 CHECK CONDITION OF CRANKSHAFT PO-
SITION SENSOR.
Turn the ignition switch to OFF.Is the crankshaft position sen-
sor installation bolt tightened
securely?Go to step 3.Tighten the crank-
shaft position sen-
sor installation bolt
securely.
3 CHECK CRANK SPROCKET.
Remove the front belt cover.Are crank sprocket teeth
cracked or damaged?Replace the crank
sprocket.
Crank Sprocket.>Go to step 4.
4 CHECK INSTALLATION CONDITION OF
TIMING BELT.
Turn the crankshaft using ST, and align align-
ment mark on crank sprocket with alignment
mark on cylinder block.
ST 499987500 CRANKSHAFT SOCKETIs the timing belt dislocated
from its proper position?Repair installation
condition of timing
belt.
Timing Belt.>Replace the crank-
shaft position sen-
sor.
Crankshaft Posi-
tion Sensor.>
Page 1308 of 2870
EN(H4SO)-210
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
BK:DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR
STUCK OFF
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
No lock-up (after engine warm-up)
No shift or excessive tight corner “braking”
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
Step Check Yes No
1 CHECK ANY OTHER DTC ON DISPLAY.Is any other DTC displayed? Inspect the rele-
vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”.
of Diagnostic Trou-
ble Code (DTC).>Go to step 2.
2 CHECK LOCK-UP DUTY SOLENOID CIR-
CUIT.
Check lock-up duty solenoid circuit.
SOLENOID, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>Is there any trouble in lock-up
duty solenoid circuit?Repair or replace
the lock-up duty
solenoid circuit.Go to step 3.
3 CHECK THROTTLE POSITION SENSOR
CIRCUIT.
Check the throttle position sensor circuit.
TION SENSOR, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>Is there any trouble in throttle
position sensor circuit?Repair or replace
the throttle posi-
tion sensor circuit.Go to step 4.
4 CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR CIRCUIT.
Check torque converter turbine speed sensor
circuit.
SENSOR, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>Is there any trouble in torque
converter turbine speed sensor
circuit?Repair or replace
the torque con-
ver ter turbine
speed sensor cir-
cuit.Go to step 5.
5 CHECK ENGINE SPEED INPUT CIRCUIT.
Check engine speed input circuit.
NAL, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>Is there any trouble in engine
speed input circuit?Repair or replace
the engine speed
input circuit.Go to step 6.
6 CHECK INHIBITOR SWITCH CIRCUIT.
Check inhibitor switch circuit.
Diagnostic Procedure without Diagnostic Trou-
ble Code (DTC).>Is there any trouble in inhibitor
switch circuit?Repair or replace
the inhibitor switch
circuit.Go to step 7.
7 CHECK BRAKE LIGHT SWITCH CIRCUIT.
Check brake light switch circuit.
Diagnostic Procedure without Diagnostic Trou-
ble Code (DTC).>Is there any trouble in brake
light switch circuit?Repair or replace
the brake light
switch circuit.Go to step 8.
Page 1385 of 2870
FU(H4DOTC)-30
FUEL INJECTION (FUEL SYSTEM)
Crankshaft Position Sensor
5. Crankshaft Position Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the bolt which installs the crankshaft
position sensor to cylinder block.
3) Remove the crankshaft position sensor, and dis-
connect the connector from it.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
T: 6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
FU-00009
FU-00056
FU-00057
FU-00058
T
Page 1388 of 2870
FU(H4DOTC)-33
FUEL INJECTION (FUEL SYSTEM)
Knock Sensor
8. Knock Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intercooler.
3) Disconnect the knock sensor connector.
4) Remove the knock sensor from cylinder block.
B: INSTALLATION
1) Install the knock sensor to cylinder block.
Tightening torque:
24 N
⋅m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
Extraction area of knock sensor cord must be posi-
tioned at a 60° angle relative to engine rear.
2) Connect the knock sensor connector.
3) Install the intercooler.
4) Connect the battery ground cable to battery.
FU-00009
FU-00062
FU-00519
(A) Front side
FU-00413
(A)
60
FU-00062
FU-00009
Page 1457 of 2870
MECHANICAL
ME(H4DOTC)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................31
3. Idle Speed .................................................................................................32
4. Ignition Timing ...........................................................................................33
5. Intake Manifold Vacuum............................................................................34
6. Engine Oil Pressure ..................................................................................35
7. Fuel Pressure ............................................................................................36
8. Valve Clearance ........................................................................................37
9. Engine Assembly ......................................................................................41
10. Engine Mounting .......................................................................................50
11. Preparation for Overhaul ...........................................................................51
12. V-belt .........................................................................................................52
13. Crank Pulley ..............................................................................................55
14. Timing Belt Cover......................................................................................57
15. Timing Belt Assembly................................................................................58
16. Cam Sprocket ...........................................................................................67
17. Crank Sprocket .........................................................................................68
18. Camshaft ...................................................................................................69
19. Cylinder Head Assembly ...........................................................................76
20. Cylinder Block ...........................................................................................84
21. Intake and Exhaust Valve .......................................................................115
22. Piston ......................................................................................................116
23. Connecting Rod ......................................................................................117
24. Crankshaft ...............................................................................................118
25. Engine Trouble in General ......................................................................119
26. Engine Noise ...........................................................................................124
Page 1459 of 2870
ME(H4DOTC)-3
MECHANICAL
General Description
CamshaftBend limit 0.020 mm (0.0079 in)
Thrust clearanceSTD 0.068 — 0.116 mm (0.0027 — 0.0046 in)
Limit 0.14 mm (0.0055 in)
Cam lobe heightIntakeSTD 44.75 — 44.85 mm (1.762 — 1.766 in)
Limit 44.65 mm (1.758 in)
ExhaustSTD 44.75 — 44.85 mm (1.762 — 1.766 in)
Limit 44.65 mm (1.758 in)
Journal O.D.
STDFront 37.946 — 37.963 mm (1.4939 — 1.4946 in)
Center
rear29.946 — 29.963 mm (1.1790 — 1.1796 in)
Oil clearanceSTD 0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit 0.10 mm (0.0039 in)
Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.3 mm (0.012 in)
Standard height 127.5 mm (5.02 in)
Va l ve s e a tRefacing angle 90°
Contacting widthIntakeSTD 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 2.2 mm (0.087 in)
Valve guideInner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Protrusion above head 15.8 — 16.2 mm (0.622 — 0.638 in)
Va l veHead edge thicknessIntakeSTD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 0.8 mm (0.031 in)
Stem diameterIntake 5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in)
Stem oil clearanceSTDIntake 0.030 — 0.057 mm (0.0012 — 0.0022 in)
Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Overall lengthIntake 104.4 mm (4.110 in)
Exhaust 104.65 mm (4.120 in)
Va l ve
springFree length 44.67 mm (1.759 in)
Squareness 2.5°, 2.0 mm (0.079 in)
Tension/spring heightSet206 — 236 N (21.0 — 24.1 kgf, 46.3 — 53.1 lb)/
36.0 mm (1.417 in)
Lift485 — 537 N (49.5 — 54.8 kgf, 109 — 121 lb)/
26.6 mm (1.047 in)
Cylinder
blockSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Cylinder bore STDA 92.005 — 92.015 mm (3.6222 — 3.6226 in)
B 91.995 — 92.005 mm (3.6218 — 3.6222 in)
TaperSTD 0.015 mm (0.0006 in)
Limit 0.050 mm (0.0020 in)
Out-of-roundnessSTD 0.010 mm (0.0004 in)
Limit 0.050 mm (0.0020 in)
Piston clearanceSTD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
Page 1464 of 2870
ME(H4DOTC)-8
MECHANICAL
General Description
Cylinder
blockSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Standard height 201.0 mm (7.91 in)
Cylinder bore STDA 99.505 — 99.515 mm (3.9175 — 3.9179 in)
B 99.495 — 99.505 mm (3.9171 — 3.9175 in)
TaperSTD 0.015 mm (0.0006 in)
Limit 0.050 mm (0.0020 in)
Out-of-roundnessSTD 0.010 mm (0.0004 in)
Limit 0.050 mm (0.0020 in)
Piston clearanceSTD−0.010 — 0.010 mm (−0.0004 — 0.0004 in)
Limit 0.030 mm (0.0012 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
Piston Outer diameterSTDA 99.505 — 99.515 mm (3.9175 — 3.9179 in)
B 99.495 — 99.505 mm (3.9171 — 3.9175 in)
0.25 mm (0.0098 in)
OS99.745 — 99.765 mm (3.9270 — 3.9278 in)
0.50 mm (0.0197 in)
OS99.995 — 100.015 mm (3.9368 — 3.9376 in)
Piston pinStandard clearance between piston
pin and hole in pistonSTD 0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit 0.020 mm (0.0008 in)
Degree of fitPiston pin must be fitted into position with thumb at 20°C
(68°F).
Piston ringPiston ring gapTop ringSTD 0.20 — 0.25 mm (0.0079 — 0.0098 in)
Limit 1.0 mm (0.039 in)
Second
ringSTD 0.37 — 0.52 mm (0.015 — 0.020 in)
Limit 1.0 mm (0.039 in)
Oil ringSTD 0.20 — 0.50 mm (0.0079 — 0.020 in)
Limit 1.5 mm (0.059 in)
Clearance between piston
ring and piston ring
grooveTop ringSTD 0.040 — 0.080 mm (0.0016 — 0.0031 in)
Limit 0.15 mm (0.0059 in)
Second
ringSTD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
Limit 0.15 mm (0.0059 in)
Connecting
rodBend twist per 100 mm (3.94 in) in
lengthLimit 0.10 mm (0.0039 in)
Side clearanceSTD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit 0.4 mm (0.016 in)
Connecting
rod bearingOil clearanceSTD 0.017 — 0.045 mm (0.0007 — 0.0018 in)
Limit 0.05 mm (0.0020 in)
Thickness at center portionSTD 1.490 — 1.502 mm (0.0587 — 0.0591 in)
0.03 mm
(0.0012
in) US1.504 — 1.512 mm (0.0592 — 0.0595 in)
0.05 mm
(0.0020
in) US1.514 — 1.522 mm (0.0596 — 0.0599 in)
0.25 mm
(0.0098
in) US1.614 — 1.622 mm (0.0635 — 0.0639 in)
Connecting
rod bushingClearance between piston pin and
bushingSTD 0 — 0.022 mm (0 — 0.0009 in)
Limit 0.030 mm (0.0012 in)