SUBARU FORESTER 2004 Service Repair Manual

EN(H4DOTC 2.5)-257
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
19 CHECK HARNESS BETWEEN ECM AND AC-
CELERATOR PEDAL POSITION SENSOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Disconnect the connector from the acceler-
ator pedal position sensor.
4) Measure the resistance between connector
terminals of accelerator pedal position sensor.
Connector & terminal
(B315) No. 5 — (B315) No. 2:Is the resistance more than 1
MΩ?Repair the poor
contact in ECM con-
nector. Replace the
ECM if defective.Repair short circuit
in harness between
ECM connector and
accelerator pedal
position sensor con-
nector. Step Check Yes No

EN(H4DOTC 2.5)-258
ENGINE (DIAGNOSTIC)
General Diagnostic Table
19.General Diagnostic Table
A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. General.>
Symptom Problem parts
1. Engine stalls during idling.1) Electronic throttle control
2) Manifold absolute pressure sensor
3) Mass air flow and intake air temperature sensor
4) Ignition parts (*1)
5) Engine coolant temperature sensor (*2)
6) Crankshaft position sensor (*3)
7) Camshaft position sensor (*3)
8) Fuel injection parts (*4)
2. Rough idling1) Electronic throttle control
2) Manifold absolute pressure sensor
3) Mass air flow and intake air temperature sensor
4) Engine coolant temperature sensor (*2)
5) Ignition parts (*1)
6) Air intake system (*5)
7) Fuel injection parts (*4)
8) Crankshaft position sensor (*3)
9) Camshaft position sensor (*3)
10) Oxygen sensor
11) Fuel pump and fuel pump relay
3. Engine does not return to idle.1) Electronic throttle control
2) Engine coolant temperature sensor
3) Manifold absolute pressure sensor
4) Mass air flow sensor
4. Poor acceleration1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Electronic throttle control
4) Fuel injection parts (*4)
5) Fuel pump and fuel pump relay
6) Engine coolant temperature sensor (*2)
7) Crankshaft position sensor (*3)
8) Camshaft position sensor (*3)
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
11) Ignition parts (*1)
5. Engine stalls or engine sags or hesitates at
acceleration.1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor (*2)
4) Crankshaft position sensor (*3)
5) Camshaft position sensor (*3)
6) Purge control solenoid valve
7) Fuel injection parts (*4)
8) Fuel pump and fuel pump relay
6. Surging1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor (*2)
4) Crankshaft position sensor (*3)
5) Camshaft position sensor (*3)
6) Fuel injection parts (*4)
7) Throttle position sensor
8) Fuel pump and fuel pump relay

EN(H4DOTC 2.5)-259
ENGINE (DIAGNOSTIC)
General Diagnostic Table
*1: Check ignition coil & ignitor ASSY and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system. 7. Spark knock1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor
4) Knock sensor
5) Fuel injection parts (*4)
6) Fuel pump and fuel pump relay
8. After burning in exhaust system1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor (*2)
4) Fuel injection parts (*4)
5) Fuel pump and fuel pump relay Symptom Problem parts

EN(H4DOTC 2.5)-260
ENGINE (DIAGNOSTIC)
General Diagnostic Table

FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL

CONTROL SYSTEM
CS
Page
1. General Description ....................................................................................2
2. Select Lever ................................................................................................8
3. Select Cable ..............................................................................................13
4. N-R Lock Solenoid ....................................................................................16
5. MT Gear Shift Lever ..................................................................................17
6. MT Drive Select Lever...............................................................................23
7. Drive Select Cable ....................................................................................25
8. General Diagnostic Table..........................................................................26

CS-2
CONTROL SYSTEM
General Description
1. General Description
A: SPECIFICATION
Item Specification
Swing torque of rod against lever N (kgf, Ib) 3.7 (0.38, 0.83) or less

CS-3
CONTROL SYSTEM
General Description
B: COMPONENT
1. AT SELECT LEVER
 NON-TURBO MODEL
CS-00367
T3
T2
T3
T1
(10) (22)
(9) (8)
(7)(6) (5) (4) (2)
(3)
(1)(22)(12)
(13)
(15)
(16)
(21) (20) (19) (17)
(14)
(11)
(18)
(23)
(24)
(1) Bulb (11) Spacer (21) Adjusting nut A
(2) Detent arm (12) Grip (22) Clip
(3) Detent spring (13) Indicator cover (23) Tube
(4) Select lever ASSY (14) Blind (24) Cover
(5) Spring pin (15) Cushion
(6) Arm ASSY (16) Guide plateTightening torque: N·m (kgf-m, ft-lb)
(7) Bushing ASSY (17) Snap pinT1: 7.5 (0.76, 5.5)
(8) Base plate (18) WasherT2: 13 (1.3, 9.4)
(9) Grommet (19) Select cableT3: 18 (1.8, 13.0)
(10) Packing (20) Adjusting nut B

CS-4
CONTROL SYSTEM
General Description
 TURBO MODEL
CS-00366
T2
T4 T4T1 T3
(31) (29) (27)(28) (20)
(25)(22) (19)
(23)
(24)(21)
(30) (20)(12)
(11)(13) (18)(3)
(17)(10)
(8)
(9)(7)
(15)
(26)(1)
(2)
(4)
(5)
(6) (33)
(32)
(14)
(16)
(1) Grip (14) Lock plate A (27) Washer
(2) Indicator cover (15) Bushing (28) Snap pin
(3) Cover (16) Lock plate C (29) Select cable
(4) Blind (17) N−R lock solenoid (30) Adjusting nut B
(5) Cushion (18) Clamp (31) Adjusting nut A
(6) Guide plate (19) Bulb (32) Cover
(7) Detent arm (20) Clip (33) Clip
(8) Detent spring (21) Arm ASSY
(9) Tube (22) Bushing ASSYTightening torque: N·m (kgf-m, ft-lb)
(10) Select lever ASSY (23) Base plate ASSYT1: 2.0 (0.2, 1.4)
(11) Lock plate B (24) GrommetT2: 7.5 (0.76, 5.5)
(12) Bushing (25) PackingT3: 13 (1.3, 9.4)
(13) Bushing (26) SpacerT4: 18 (1.8, 13.0)

CS-5
CONTROL SYSTEM
General Description
2. MT GEAR SHIFT LEVER
(1) Gear shift knob (11) Bushing A (21) Boot & insulator ASSY
(2) Console boot (12) Spring pin (22) Front cover
(3) Plate ASSY (13) Cushion rubber (23) Clamp
(4) Gear shift lever (14) Bushing B
(5) Bushing (15) JointTightening torque: N·m (kgf-m, ft-lb)
(6) Bushing (16) RodT1: 7.5 (0.76, 5.5)
(7) Lock wire (17) BracketT2: 12 (1.2, 8.7)
(8) Boot (18) WasherT3: 18 (1.8, 13.0)
(9) Snap ring (19) Stay
(10) O-ring (20) Spacer
CS-00357
T2
(5) (5)
(5) (5)
(4)
(6)(3) (2)(1)
(18)(21)(23) (22)
(20)
(19)(17)T1
(14)
(13) (16)
(15)
(12) (12)
(11)
(10)
(10)
(9)(8)
(7)
T3
T3
T3
T3