meter 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 1841 of 2870
EN(H4DOTC)-208
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK TRANSMISSION TYPE.Is the transmission type AT? Go to step 2.Go to step 3.
2 CHECK SPEEDOMETER OPERATION IN
COMBINATION METER.Does speedometer operate
normally?Go to step 3.Check the speed-
ometer.
eter.>
3 CHECK HARNESS BETWEEN ECM AND
COMBINATION METER CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from the combi-
nation meter.
3) Measure the resistance between ECM and
combination meter connector.
Connector & terminal
(B134) No. 1 — (i11) No. 2:Is the resistance less than 10
Ω?Repair the poor
contact in ECM
connector.Repair the har-
ness and connec-
tor.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
ECM and combi-
nation meter con-
nector
Poor contact in
ECM connector.
Poor contact in
combination meter
connector
Poor contact in
coupling connector
Page 1849 of 2870
EN(H4DOTC)-216
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK THROTTLE CABLE.Does the throttle cable have
play for adjustment?Go to step 2.Adjust throttle
cable.
Accelerator Con-
trol Cable.>
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. 27 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 3.Go to step 4.
3 CHECK OUTPUT SIGNAL FROM ECM.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from idle air con-
trol solenoid valve.
3) Turn the ignition switch to ON.
4) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B134) No. 27 (+) — Chassis ground (
−):Is the voltage more than 10 V? Repair battery
short circuit in har-
ness between
ECM and idle air
control solenoid
valve connec-
tor.After repair,
replace the ECM.
Engine Control
Module (ECM).>Replace the idle
air control solenoid
valve and ECM.
Idle Air Control
Solenoid Valve.>
Engine Control
Module (ECM).>
4 CHECK OUTPUT SIGNAL FROM ECM.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(B134) No. 27 (+) — Chassis ground (
−):Does the voltage change by
shaking the harness and con-
nector of ECM while monitor-
ing the value with voltage
meter?Repair battery
short circuit in har-
ness between
ECM and idle air
control solenoid
valve connec-
tor.After repair,
replace the ECM.
Engine Control
Module (ECM).>Contact the SUB-
ARU dealer.
N
OTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
Page 1883 of 2870
EN(H4DOTC)-250
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK CURRENT DATA.
1) Start the engine.
2) Read the data of throttle position sensor
signal using Subaru Select Monitor or OBD-II
general scan tool.
N
OTE:
Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”.
OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.Is the voltage less than 0.1 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.A tempo-
rary poor contact
of the connector
may be the cause.
N
OTE:
In this case repair
the following:
Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector.
Poor contact in
coupling connector
2 CHECK INPUT SIGNAL FROM ECM.
Measure the voltage between ECM connector
and chassis ground while tumble generator
valve is fully closed.
Connector & terminal
(B136) No. 16 (+) — Chassis ground (
−):Is the voltage more than 4.5 V? Go to step 4.Go to step 3.
3 CHECK INPUT SIGNAL FROM ECM.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(B136) No. 16 (+) — Chassis ground (
−):Does the voltage change by
shaking the harness and con-
nector of ECM while monitor-
ing the value with voltage
meter?Repair the poor
contact in ECM
connector.Contact the SUB-
ARU dealer.
N
OTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
4 CHECK INPUT SIGNAL FROM ECM.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(B136) No. 26 (+) — Chassis ground (
−):Is the voltage less than 0.1 V? Go to step 6.Go to step 5.
5 CHECK INPUT SIGNAL FOR ECM (WITH
SUBARU SELECT MONITOR).
Measure the voltage between ECM connector
and chassis ground.Does the voltage change by
shaking the harness and con-
nector of ECM while monitor-
ing the value with Subaru
Select Monitor?Repair the poor
contact in ECM
connector.Go to step 6.
Page 1890 of 2870
EN(H4DOTC)-257
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK CURRENT DATA.
1) Start the engine.
2) Read the data of tumble generator valve
position sensor signal using Subaru Select
Monitor or OBD-II general scan tool.
N
OTE:
Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”.
OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.Is the voltage less than 0.1 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.A tempo-
rary poor contact
of the connector
may be the cause.
N
OTE:
In this case repair
the following:
Poor contact in
tumble generator
valve position sen-
sor connector
Poor contact in
ECM connector.
Poor contact in
coupling connector
2 CHECK INPUT SIGNAL FROM ECM.
Measure the voltage between ECM connector
and chassis ground while throttle valve is fully
closed.
Connector & terminal
(B136) No. 16 (+) — Chassis ground (
−):Is the voltage more than 4.5 V? Go to step 4.Go to step 3.
3 CHECK INPUT SIGNAL FROM ECM.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(B136) No. 16 (+) — Chassis ground (
−):Does the voltage change by
shaking the harness and con-
nector of ECM while monitor-
ing the value with voltage
meter?Repair the poor
contact in ECM
connector.Contact the SUB-
ARU dealer.
N
OTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
4 CHECK INPUT SIGNAL FROM ECM.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(B136) No. 27 (+) — Chassis ground (
−):Is the voltage less than 0.1 V? Go to step 6.Go to step 5.
5 CHECK INPUT SIGNAL FOR ECM (WITH
SUBARU SELECT MONITOR).
Measure the voltage between ECM connector
and chassis ground.Does the voltage change by
shaking the harness and con-
nector of ECM while monitor-
ing the value with Subaru
Select Monitor?Repair the poor
contact in ECM
connector.Go to step 6.
Page 1993 of 2870
FU(H4DOTC 2.5)-63
FUEL INJECTION (FUEL SYSTEM)
Fuel System Trouble in General
31.Fuel System Trouble in General
A: INSPECTION
NOTE:
When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.
To prevent water condensation.
(1) Top off the fuel tank or drain the fuel completely.
(2) Drain the water condensation from the fuel filter.
Refilling the fuel tank.
Refill the fuel tank while there is still some fuel left in the tank.
Protecting the fuel system against freezing and water condensation.
(3) Cold areas:
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below
0°C (32°F) throughout the winter season, use an anti-freeze solution in the cooling system. Refueling will
also complement the effect of anti-freeze solution each time the fuel level drops to about one-half. After
the winter season, drain the water which may have accumulated in the fuel filter and fuel tank in the man-
ner same as that described under “Affected areas” below.
(4) Affected areas:
When the water condensation is notched in the fuel filter, drain the water from both the fuel filter and fuel
tank or use a water removing agent (or anti-freeze solution) in the fuel tank.
Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water remov-
ing agent) container before use.
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
❍Defective terminal contact.Inspect connections, especially ground, and tighten
securely.
❍Trouble in electromagnetic or electronic circuit parts. Replace the fuel pump.
2) Lowering of fuel pump function. Replace the fuel pump.
3) Clogged dust or water in the fuel filter. Replace the fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace the fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace the air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
5) Clogged or bent air breather tube or air vent tube.Clean, correct or replace the air breather tube or air vent
tube.
3. Gasoline smell inside of compartment
1)Loose joints at air breather tube, air vent tube and fuel filler
pipe.Retightening.
2) Defective packing air tightness on the fuel saucer. Correct or replace the packing.
3) Cracked fuel separator. Replace the separator.
4) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
Page 2026 of 2870
EN(H4DOTC 2.5)-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 Start Fail-
ure”.
54, 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”.
258, General Diag-
nostic 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.
65, List of Diag-
nostic Trouble
Code (DTC).> Go
to step 4.Repair the related
parts.
N
OTE:
If DTC is not shown
on display although
the malfunction in-
dicator light illumi-
nates, perform the
diagnostics for mal-
function indicator
light circuit or com-
bination meter.
45, Malfunction In-
dicator Light.>
4 PERFORM THE DIAGNOSIS.
1) Perform clear memory mode.
2) Perform the “INSPECTION MODE”.
tor or OBD-II general scan tool
indicate DTC?Check on “Diag-
nostic Chart with
Diagnostic Trou-
ble Code (DTC)”.
70, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>Finish the diagno-
sis.
Page 2027 of 2870
EN(H4DOTC 2.5)-3
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 Radio❏ ON / ❏ OFF
A/C compressor❏ ON / ❏ OFF CD/Cassette❏ ON / ❏ OFF
Radiator fan❏ ON / ❏ OFF Car phone❏ ON / ❏ OFF
Fr o nt wi pe r❏ ON / ❏ OFF CB❏ ON / ❏ OFF
Rear Wiper❏ ON / ❏ OFF
Page 2029 of 2870
EN(H4DOTC 2.5)-5
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 airbag system wiring harness and con-
nectors are all colored 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 gener-
ated 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 OFF the igni-
tion switch.
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 damaging 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, take care not to allow water
to get into the connectors when washing the vehi-
cle, or when servicing the vehicle on a rainy day. 8) Use ECM mounting stud bolts on the body head
grounding point when measuring voltage and resis-
tance inside the passenger compartment.
9) Use engine ground terminal or engine proper as
the grounding point to the body when measuring
voltage and resistance in the engine compartment.
10) Every MFI-related part is a precision part. Do
not drop them.
11) 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 instrument panel lower trim panel.)
The antenna feeder must be placed as far
apart as possible from the ECM and MFI har-
ness.
Carefully adjust the antenna for correct match-
ing.
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.
12) 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.
(A) Stud bolt
EN-00069
(A)
EN-01201
Page 2030 of 2870
EN(H4DOTC 2.5)-6
ENGINE (DIAGNOSTIC)
General Description
13) 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.
14) 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 ground terminal is properly
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.
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.
EN-01201
Page 2031 of 2870
EN(H4DOTC 2.5)-7
ENGINE (DIAGNOSTIC)
General Description
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.
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