SUBARU FORESTER 2004 Service Repair Manual
Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 1821 of 2870
EN(H4DOTC)-188
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AX:DTC P0458 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-
TROL VALVE CIRCUIT LOW
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
WIRING DIAGRAM:
EN-02335
MAIN RELAY
B47 1 2 3 5 4 6
BATTERY
E
B61F44
F60
: LHD
E3
F44B47
B134
B134
E4
PURGE CONTROL
SOLENOID VALVEECM
14 2 1
7LHD
RHD
LHD
RHDSBF-5123456783412
56
2 1
B200
F74
RHD
RHD
LHD LHD
B100
F2
RHD
RHD
1
5LHD LHD
: LHD
: RHD
123
4
56
78
9
1011 12
1314 15 16
B21
E4
F60
12
F74
B21
: RHD34
128910 11
12 13 14 15 16 17 18 19 20 21 22 23 2456 7
F2 : LHD
E2
: RHD
1234 5678910 11 12 13 14 15 16 17 18 19 20
56 7
82 1
94 310
24 22 23 25 11 12 13 14 15
26 27
2816 17
18 19 20 21
33 34 29
32 30 31
Page 1822 of 2870
EN(H4DOTC)-189
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK OUTPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.
2) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B134) No. 14 (+) — Chassis ground (
−):Is the voltage more than 10 V? Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time.Go to step 2.
2 CHECK HARNESS BETWEEN PURGE CON-
TROL SOLENOID VALVE AND ECM CON-
NECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connectors from purge con-
trol solenoid valve and ECM.
3) Measure the resistance of harness
between purge control solenoid valve connec-
tor and engine ground.
Connector & terminal
(E4) No. 2 — Engine ground:Is the resistance more than 1
MΩ?Go to step 3.Repair ground
short circuit in har-
ness between
ECM and purge
control solenoid
valve connector.
3 CHECK HARNESS BETWEEN PURGE CON-
TROL SOLENOID VALVE AND ECM CON-
NECTOR.
Measure the resistance of harness between
ECM and purge control solenoid valve of har-
ness connector.
Connector & terminal
(B134) No. 14 — (E4) No. 2:Is the resistance less than 1
Ω?Go to step 4.Repair open circuit
in harness
between ECM and
purge control sole-
noid valve connec-
tor.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
ECM and purge
control solenoid
valve connector
Poor contact in
coupling connector
4 CHECK PURGE CONTROL SOLENOID
VALVE.
1) Remove the purge control solenoid valve.
2) Measure the resistance between purge
control solenoid valve terminals.
Te r m i n a l s
No. 1 — No. 2:Is the resistance 10 — 100 Ω? Go to step 5.Replace the purge
control solenoid
valve.
Purge Control
Solenoid Valve.>
5 CHECK POWER SUPPLY TO PURGE CON-
TROL SOLENOID VALVE.
1) Turn the ignition switch to ON.
2) Measure the voltage between purge control
solenoid valve and engine ground.
Connector & terminal
(E4) No. 1 (+) — Engine ground (
−):Is the voltage more than 10 V? Go to step 6.Repair open circuit
in harness
between main
relay and purge
control solenoid
valve connector.
6 CHECK POOR CONTACT.
Check poor contact in purge control solenoid
valve connector.Is there poor contact in purge
control solenoid valve connec-
tor?Repair poor con-
tact in purge con-
trol solenoid valve
connector.Contact the SUB-
ARU dealer.
N
OTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
Page 1823 of 2870
EN(H4DOTC)-190
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AY:DTC P0459 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-
TROL VALVE CIRCUIT HIGH
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
WIRING DIAGRAM:
EN-02335
MAIN RELAY
B47 1 2 3 5 4 6
BATTERY
E
B61F44
F60
: LHD
E3
F44B47
B134
B134
E4
PURGE CONTROL
SOLENOID VALVEECM
14 2 1
7LHD
RHD
LHD
RHDSBF-5123456783412
56
2 1
B200
F74
RHD
RHD
LHD LHD
B100
F2
RHD
RHD
1
5LHD LHD
: LHD
: RHD
123
4
56
78
9
1011 12
1314 15 16
B21
E4
F60
12
F74
B21
: RHD34
128910 11
12 13 14 15 16 17 18 19 20 21 22 23 2456 7
F2 : LHD
E2
: RHD
1234 5678910 11 12 13 14 15 16 17 18 19 20
56 7
82 1
94 310
24 22 23 25 11 12 13 14 15
26 27
2816 17
18 19 20 21
33 34 29
32 30 31
Page 1824 of 2870
EN(H4DOTC)-191
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK OUTPUT SIGNAL FROM ECM.
1) Turn the ignition switch to OFF.
2) Connect the test mode connector at the
lower portion of instrument panel (on the
driver’s side).
3) Turn the ignition switch to ON.
4) While operating the purge control solenoid
valve, measure voltage between ECM and
chassis ground.
N
OTE:
Purge control solenoid valve operation can be
executed using Subaru Select Monitor.For the
procedure, refer to “Compulsory Valve Opera-
tion Check Mode”.
Connector & terminal
(B134) No. 14 (+) — Chassis ground (
−):Is the voltage 0 — 13 V? Go to step 2.Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time.In this
case, repair poor
contact in ECM
connector.
2 CHECK OUTPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.
2) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B134) No. 14 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 4.Go to step 3.
3 CHECK POOR CONTACT.
Check poor contact in ECM connector. Is there poor contact in ECM
connector?Repair the poor
contact in ECM
connector.Replace the ECM.
Engine Control
Module (ECM).>
4 CHECK HARNESS BETWEEN PURGE CON-
TROL SOLENOID VALVE AND ECM CON-
NECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from purge con-
trol solenoid valve.
3) Turn the ignition switch to ON.
4) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B134) No. 14 (+) — Chassis ground (
−):Is the voltage more than 10 V? Repair battery
short circuit in har-
ness between
ECM and purge
control solenoid
valve connec-
tor.After repair,
replace the ECM.
Engine Control
Module (ECM).>Go to step 5.
5 CHECK PURGE CONTROL SOLENOID
VALVE.
1) Turn the ignition switch to OFF.
2) Measure the resistance between purge
control solenoid valve terminals.
Te r m i n a l s
No. 1 — No. 2:Is the resistance less than 1
Ω?Replace the purge
control solenoid
valve and ECM.
Purge Control
Solenoid Valve.>
Engine Control
Module (ECM).>Go to step 6.
6 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair the poor
contact in ECM
connector.Replace the ECM.
Engine Control
Module (ECM).>
Page 1825 of 2870
EN(H4DOTC)-192
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AZ:DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
WIRING DIAGRAM:
B72
R59R58
F60 : LHD
B21 : RHD
i10
B136
i11
1
23456789
10
R15
B136
ECM
i10
B38
B100F2F60E3
E2
B99
R3
i3
EE
E
RHD
RHD
LHD
FUEL
GAUGE
B :
i11 C :
C : B : COMBINATION
METER
B9 B10
C1
3*
*4
R15
R59
FUEL SUB
LEVEL SENSOR
R572
1
2R583
53
FUEL LEVEL
SENSOR
9
B21
16
16 20
3412
1213
4562123
4
56
78
9
1011 12
1314 15 16
F2LHD : 28
RHD : 20
LHD : 16
RHD : 2
*1
*2
LHD : 4
RHD : 3
LHD : 5
RHD : 17*3
*4
EN-02336
3412i3B98B37
B99
56
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35
1234567891011121314151617181920212223242526272829301234 5678910 11 12 13 14 15 16 17 18 19 20123
45678
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
2534
12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 2456 7
: LHDB98
: RHD
: LHD
R2
: RHD
1*2*
B37
i223
IGNITION SWITCH
SBF-4SBF-1
B72
14
E
No.14
RHD
B38
i316
LHD
LHD
RHDBATTERY
Page 1826 of 2870
EN(H4DOTC)-193
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 rele-
vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”.
List of Diagnostic
Trouble Code
(DTC).>
N
OTE:
In this case, it is
not necessary to
inspect DTC
P0461.Replace the fuel
level sensor and
fuel sub level sen-
sor.
Fuel Level Sen-
sor.>
Fuel Sub Level
Sensor.>
Page 1827 of 2870
EN(H4DOTC)-194
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
BA:DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
WIRING DIAGRAM:
B72
R59R58
F60 : LHD
B21 : RHD
i10
B136
i11
1
23456789
10
R15
B136
ECM
i10
B38
B100F2F60E3
E2
B99
R3
i3
EE
E
RHD
RHD
LHD
FUEL
GAUGE
B :
i11 C :
C : B : COMBINATION
METER
B9 B10
C1
3*
*4
R15
R59
FUEL SUB
LEVEL SENSOR
R572
1
2R583
53
FUEL LEVEL
SENSOR
9
B21
16
16 20
3412
1213
4562123
4
56
78
9
1011 12
1314 15 16
F2LHD : 28
RHD : 20
LHD : 16
RHD : 2
*1
*2
LHD : 4
RHD : 3
LHD : 5
RHD : 17*3
*4
EN-02336
3412i3B98B37
B99
56
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35
1234567891011121314151617181920212223242526272829301234 5678910 11 12 13 14 15 16 17 18 19 20123
45678
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
2534
12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 2456 7
: LHDB98
: RHD
: LHD
R2
: RHD
1*2*
B37
i223
IGNITION SWITCH
SBF-4SBF-1
B72
14
E
No.14
RHD
B38
i316
LHD
LHD
RHDBATTERY
Page 1828 of 2870
EN(H4DOTC)-195
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK SPEEDOMETER AND TACHOME-
TER OPERATION IN COMBINATION
METER.Does the speedometer and
tachometer operate normally?Go to step 2.Repair or replace
the combination
meter.
Meter System.>
2 CHECK INPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.(engine OFF)
2) Measure the voltage between ECM con-
nector and chassis ground.
Connector & terminal
(B136) No. 20 (+) — Chassis ground (
−):Is the voltage less than 0.12
V?Go to step 4.Go to step 3.
3 CHECK INPUT SIGNAL FOR ECM (WITH
SUBARU SELECT MONITOR).
Read the data of fuel level sensor signal using
Subaru Select Monitor.
N
OTE:
Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”.
shaking the harness and con-
nector of ECM while monitor-
ing the value with Subaru
Select Monitor?Repair the poor
contact in ECM
connector.Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time.A tempo-
rary poor contact
of the connector
may be the cause.
N
OTE:
In this case repair
the following:
Poor contact in
combination meter
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
4 CHECK INPUT VOLTAGE OF ECM.
1) Turn the ignition switch to OFF.
2) Separate fuel tank cord connector (R57)
and rear wiring harness connector (R15).
3) Turn the ignition switch to ON.
4) Measure the voltage of harness between
ECM connector and chassis ground.
Connector & terminal
(B136) No. 20 (+) — Chassis ground (
−):Is the voltage more than 0.12
V?Go to step 5.Go to step 6.
5 CHECK HARNESS BETWEEN ECM AND
COMBINATION METER.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from connector
(i10), (i11) and ECM connector.
3) Measure the resistance between ECM and
chassis ground.
Connector & terminal
(B136) No. 20 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 7.Repair the ground
short in harness
between ECM and
combination meter
connector.
6 CHECK HARNESS BETWEEN ECM AND
COMBINATION METER.
Measure the resistance between ECM and
combination meter connector.
Connector & terminal
(B136) No. 20 — (i11) No. 1:Is the resistance less than 10
Ω?Repair or replace
the combination
meter.
Meter System.>Repair open circuit
between ECM and
combination meter
connector.
N
OTE:
In this case repair
the following:
Poor contact in
coupling connector
Page 1829 of 2870
EN(H4DOTC)-196
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
7 CHECK FUEL TANK CORD.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from fuel sub
level sensor.
3) Measure the resistance between fuel sub
level sensor and chassis ground.
Connector & terminal
(R59) No. 1 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 8.Repair ground
short circuit in fuel
tank cord.
8 CHECK FUEL TANK CORD.
1) Disconnect the connector from fuel pump
assembly.
2) Measure the resistance between fuel pump
assembly and chassis ground.
Connector & terminal
(R59) No. 2 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 9.Repair ground
short circuit in fuel
tank cord.
9 CHECK FUEL LEVEL SENSOR.
1) Remove the fuel pump assembly.
2) Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Te r m i n a l s
No. 3 — No. 5:Is the resistance 0.5 — 2.5 Ω? Go to step 10.Replace the fuel
level sensor.
10 CHECK FUEL SUB LEVEL SENSOR.
1) Remove the fuel sub level sensor.
2) Measure the resistance between fuel sub
level sensor and terminals with its float set to
the full position.
Te r m i n a l s
No. 1 — No. 2:Is the resistance 0.5 — 2.5 Ω? Repair poor con-
tact in harness
between ECM and
combination meter
connector.Replace the fuel
sub level sensor. Step Check Yes No
Page 1830 of 2870
EN(H4DOTC)-197
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
BB:DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
WIRING DIAGRAM:
B72
R59R58
F60 : LHD
B21 : RHD
i10
B136
i11
1
23456789
10
R15
B136
ECM
i10
B38
B100F2F60E3
E2
B99
R3
i3
EE
E
RHD
RHD
LHD
FUEL
GAUGE
B :
i11 C :
C : B : COMBINATION
METER
B9 B10
C1
3*
*4
R15
R59
FUEL SUB
LEVEL SENSOR
R572
1
2R583
53
FUEL LEVEL
SENSOR
9
B21
16
16 20
3412
1213
4562123
4
56
78
9
1011 12
1314 15 16
F2LHD : 28
RHD : 20
LHD : 16
RHD : 2
*1
*2
LHD : 4
RHD : 3
LHD : 5
RHD : 17*3
*4
EN-02336
3412i3B98B37
B99
56
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35
1234567891011121314151617181920212223242526272829301234 5678910 11 12 13 14 15 16 17 18 19 20123
45678
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
2534
12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 2456 7
: LHDB98
: RHD
: LHD
R2
: RHD
1*2*
B37
i223
IGNITION SWITCH
SBF-4SBF-1
B72
14
E
No.14
RHD
B38
i316
LHD
LHD
RHDBATTERY