stop start SUBARU FORESTER 2004 Service Owner's Manual

EN(H4SO)-42
ENGINE (DIAGNOSTIC)
Drive Cycle
13.Drive Cycle
A: OPERATION
There are three driving patterns on diagnosis. Fol-
lowing trouble can be diagnosed with driving spec-
ified patterns. After repair the following trouble, be
sure to check that the trouble is cleared correctly by
the driving specified patterns.
1. PREPARATION FOR DRIVE CYCLE
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) After clearing the memory, check for any remain-
ing unresolved trouble data. 44, Clear Memory Mode.>
3) Separate the test mode connector.
NOTE:
 Be sure to perform the diagnosis after idling from
starting the cooled engine except when the engine
coolant temperature is specified.
 Perform the diagnosis twice when the DTC is
marked with *. After the completion of first diagno-
sis, stop the engine and perform the second diag-
nosis on same condition.
2. DRIVE THE VEHICLE 20 MINUTES AT THE SPEED OF 80 KM/H (50 MPH), AND THEN IDLE
THE ENGINE 1 MINUTE.
3. 10 MINUTES IDLING
NOTE:
Drive the vehicle more than 4 km/h (6 MPH) before diagnosis.
DTC Item On condition
*P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1) —
*P0111Intake Air Temperature Sensor Circuit Range/Per-
formance ProblemEngine coolant temperature at start is less than 30°C (86°F)
*P0125Insufficient coolant temperature for closed loop
fuel controlEngine coolant temperature at start is less than 20°C (68°F)
*P0130O
2 Sensor Circuit (Bank 1 Sensor 1)
—
*P0133O
2 Sensor Circuit Slow Response (Bank 1 Sensor
1)—
*P0420Catalyst System Efficiency Below Threshold
(Bank 1)—
P0459Evaporative Emission Control System Purge Con-
trol Valve Circuit High—
*P0461 Fuel Level Sensor Circuit Range/Performance —
*P0464 Fuel Level Sensor Circuit Intermittent —
*P1137O
2 Sensor Circuit (Bank 1 Sensor 1)
—
DTC Item On condition
*P0483 Cooling Fan Rationality Check —
*P0506 Idle Control System RPM Lower Than Expected —
*P0507 Idle Control System RPM Higher Than Expected —

ME(H4DOTC)-32
MECHANICAL
Idle Speed
3. Idle Speed
A: INSPECTION
1. USING SUBARU SELECT MONITOR
1) Before checking the idle speed, check the fol-
lowing:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and that the hoses are
connected properly.
(2) Ensure the malfunction indicator light does
not illuminate.
2) Warm-up the engine.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) Insert the cartridge to Subaru Select Monitor.
5) Connect the Subaru Select Monitor to data link
connector.
6) Turn the ignition switch to ON, and Subaru Se-
lect Monitor switch to ON.
7) Select the {2. Each System Check} in Main
Menu.
8) Select the {Engine Control System} in Selection
Menu.
9) Select the {1. Current Data Display & Save} in
Engine Control System Diagnosis.
10) Select the {1.12 Data Display} in Data Display
Menu.
11) Start the engine, and then read the engine idle
speed.
12) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed [No load and gears in neutral]:
700
±100 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to “ON” and operate the
compressor for at least 1 minute before measure-
ment.)
Idle speed [A/C “ON”, no load and gears in neu-
tral]:
A/C Refrigerant pressure (LOW)
MT: 725
±100 rpm
AT: 750
±100 rpm
A/C Refrigerant pressure (HIGH)
MT: 800
±100 rpm
AT: 825
±100 rpm
NOTE:
As idle speed is controlled by the automatic adjust-
ment type, it can not be adjusted manually. If the
idle speed is out of specifications, refer to General
On-board Diagnosis Table under “Engine Control
System”. tics Procedure.>

ME(H4DOTC)-33
MECHANICAL
Ignition Timing
4. Ignition Timing
A: INSPECTION
1. USING SUBARU SELECT MONITOR
1) Before checking the ignition timing speed, check
the following:
(1) Ensure the air cleaner element is free from
clogging, spark plugs are in good condition, and
that hoses are connected properly.
(2) Ensure the malfunction indicator light does
not illuminate.
2) Warm-up the engine.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) Insert the cartridge to Subaru Select Monitor.
5) Connect the Subaru Select Monitor to data link
connector.
6) Turn the ignition switch to ON, and Subaru Se-
lect Monitor switch to ON.
7) Select the {2. Each System Check} in Main
Menu.
8) Select the {Engine Control System} in Selection
Menu.
9) Select the {1. Current Data Display & Save} in
Engine Control System Diagnosis.
10) Select the {1.12 Data Display} in Data Display
Menu.
11) Start the engine and check the ignition timing at
idle speed.
Ignition timing [BTDC/rpm]:
2.0 L model
12
°±10°/700
2.5 L model
17
°±10°/700
If the timing is not correct, check the ignition control
system. Refer to Engine Control System. EN(H4DOTC)-2, Basic Diagnostics Procedure.>

ME(H4DOTC)-45
MECHANICAL
Engine Assembly
26) Support the transmission with a garage jack.
NOTE:
Before moving the engine away from transmission,
check to be sure no work has been overlooked. Do-
ing this is very important in order to facilitate re-in-
stallation and because transmission lowers under
its own weight.
27) Separation of the engine and transmission.
(1) Remove the starter. REMOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT model)
ST 498277200 STOPPER SET
(3) Remove the bolts which hold the right upper
side of transmission to engine.
28) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until the main-
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil pressure gauge, etc.
29) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the clutch release fork and bearing onto
transmission. (MT model)
(1) Remove the release bearing from clutch
cover with flat type screw driver.
(2) Install the release bearing on transmission.
(3) Install the release fork into release bearing
tab.
ME-00048
ST
ME-00049
ME-00050
(A) Release fork
(B) Release bearing
ME-00051
ME-00052
(A)
(B)

ME(H4DOTC)-47
MECHANICAL
Engine Assembly
6) Remove the garage jack.
7) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
8) Remove the ST from torque converter clutch
case. (AT model)
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
ST 498277200 STOPPER SET
9) Install the starter. STALLATION, Starter.>
10) Install the torque converter clutch onto drive
plate. (AT model)
(1) Tighten the bolts which hold the torque con-
verter clutch to drive plate.
(2) Tighten other bolts while rotating the engine
by using ST.
CAUTION:
Be careful not to drop bolts into the torque con-
verter clutch housing.
ST 499977300 CRANK PULLEY WRENCHTightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Clog the service hole with plug.
11) Install the fuel filter and bracket.
12) Install the power steering pump on bracket.
(1) Install the reservoir tank on bracket.
(2) Install the power steering pump.
Tightening torque:
20.1 N
⋅m (2.05 kgf-m, 14.8 ft-lb)
ME-00047
T1
T2
MT-00085ME-00044
ME-00046
ME-00038
ME-00037

EN(H4DOTC)-7
ENGINE (DIAGNOSTIC)
General Description
12) 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 instru-
ment 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
matching.
 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.
13) 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.
14) Problems in the electronic-controlled automatic
transmission may be caused by failure of the en-
gine, the electronic control system, the transmis-
sion proper, or by a combination of these.These
three causes (engine, electronic control system,
transmission) must be distinguished clearly when
performing diagnostics.
15) 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.
16) 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 1.2602) 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.
EN-00070

EN(H4DOTC)-45
ENGINE (DIAGNOSTIC)
Drive Cycle
13.Drive Cycle
A: OPERATION
There are three driving patterns on diagnosis.Following trouble can be diagnosed with driving specified pat-
terns.After repair the following trouble, be sure to check that the trouble is cleared correctly by the driving
specified patterns.
1. PREPARATION FOR DRIVE CYCLE
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) After performing the diagnostics and clearing the memory, check for any remaining unresolved trouble da-
ta.
3) Separate the test mode connector.
NOTE:
 Be sure to perform the diagnosis after idling from starting the cooled engine except when the engine cool-
ant temperature is specified.
 Perform the diagnosis twice when the DTC is marked * and after the completion of first diagnosis, stop the
engine and perform the second diagnosis in the same condition.
2. DRIVE THE VEHICLE 20 MINUTES AT THE SPEED OF 80 KM/H (50 MPH), AND THEN IDLE
THE ENGINE 1 MINUTE.
3. 10 MINUTES IDLING
NOTE:
Drive the vehicle more than 10 km/h (6 MPH) before diagnosis.
DTC Item On condition
*P0125 Insufficient Coolant Temperature For Closed Loop Fuel ControlEngine coolant temperature at
start is less than 20°C (68°F)
*P0133O
2 Sensor Circuit Slow Response (Bank 1 Sensor 1)
—
*P0420 Catalyst System Efficiency Below Threshold (Bank 1) —
P0459 Evaporative Emission Control System Purge Control Valve Circuit High —
P0461 Fuel Level Sensor Circuit Range/Performance —
P0546 Exhaust Gas Temperature Sensor Circuit High - Bank 1 —
P1312 Exhaust Gas Temperature Sensor MalfunctionEngine coolant temperature at
start is less than 30°C (86°F)
DTC Item On condition
P0111 Intake Air Temperature Circuit Range/Performance —
P0464 Fuel Level Sensor Circuit Intermittent —
P0508 Idle Control System Circuit Low —
*P0483 Cooling Fan Rationality Check —
*P0506 Idle Control System RPM Lower Than Expected —
*P0507 Idle Control System RPM Higher Than Expected —

EN(H4DOTC)-46
ENGINE (DIAGNOSTIC)
Drive Cycle
4. DRIVE THE VEHICLE WITH FOLLOWING DRIVE PATTERNS
(A) Run the engine at idle for more
than 10 seconds.(D) Slowdown the vehicle to 64 km/h
(40 MPH) with throttle fully closed
condition.(F) Accelerate the vehicle to 97 km/h
(60 MPH) within 10 seconds.
(B) Accelerate the vehicle to 97 km/h
(60 MPH) within 20 seconds.(G) Stop the vehicle with throttle fully
closed condition. (E) Drive the vehicle at 64 km/h (40
MPH) for 20 seconds.
(C) Drive the vehicle at 97 km/h (60
MPH) for 20 seconds.(H) Vehicle speed km/h (MPH)
(I) (Sec.)
DTC Item On condition
P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1) —
P0068 Manifold Pressure Sensor Range/Performance —
P0246 Turbo/Super Charger Wastegate Solenoid “A” High —
P1090 Tumble Generated Valve System 1 (Valve Open)Engine coolant temperature at
start is −5 — 5°C (−41 — 41°F)
P1092 Tumble Generated Valve System 2 (Valve Open)Engine coolant temperature at
start is −5 — 5°C (−41 — 41°F)
*P0121 Throttle/Pedal Position Sensor/Switch “A” Circuit Range/Performance —
*P0139O
2 Sensor Circuit Slow Response (Bank 1 Sensor 2)
—
*P0301 Cylinder 1 Misfire DetectedDiagnosis may be completed at
once
*P0302 Cylinder 2 Misfire DetectedDiagnosis may be completed at
once
*P0303 Cylinder 3 Misfire DetectedDiagnosis may be completed at
once
*P0304 Cylinder 4 Misfire DetectedDiagnosis may be completed at
once
*P0101 Mass or Volume Air Flow Circuit Range/Performance —
P0244 Turbo/Super Charger Wastegate Solenoid “A” Range/Performance —
P1301 Misfire Detected (High Temperature Exhaust Gas) —
EN-00842
(C) (H)
(I) (60)
97
64(40)
(B)
(A)(F) (D)
(E)
150 100 50 0(G)

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

EN(H4DOTC 2.5)-29
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
NOTE:
For detailed operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MANUAL”.
Mass air flow sensor signal Air Flow Sensor Voltage V
AT/MT identification signal AT Vehicle ID Signal ON or OFF
ETC motor relay ETC Motor Relay ON or OFF
Clutch SW Clutch Switch ON or OFF
Stop Light SW Stop Light Switch ON or OFF
SET/COAST SW SET/COAST Switch ON or OFF
RESUME/ACCEL SW RESUME/ACCEL Switch ON or OFF
Brake SW Brake Switch ON or OFF
Main SW Main Switch ON or OFF
Ignition switch signal Ignition Switch ON or OFF
Test Mode Signal Test Mode Signal ON or OFF
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal A/C Switch ON or OFF
Air conditioning signal A/C Compressor Signal ON or OFF
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF
Knocking signal Knocking Signal ON or OFF
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF
Power steering switch signal P/S Switch ON or OFF
Rear oxygen sensor rich signalRear O
2 Rich Signal
ON or OFF
Starter switch signal Starter Switch ON or OFF
Idle switch signal Idle Switch Signal ON or OFF
Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF
Camshaft position sensor signal Camshaft Position Sig. ON or OFF
Rear defogger switch signal Rear Defogger SW ON or OFF
Blower fan switch signal Blower Fan SW ON or OFF
Small light switch signal Light Switch ON or OFF
Handle switch signal Handle Switch —
Wiper switch signal Wiper Switch ON or OFF
A/C mid pressure switch signal A/C mid Pressure Switch ON or OFF
AT coordinate retard angle demand Retard Signal form AT ON or OFF
AT coordinate fuel cut demand Fuel Cut Signal from AT ON or OFF
AT coordinate permission signal Torque Permission Signal ON or OFF
UDC not torque down output Ban of Torque Down ON or OFF
UDC torque down demand Request Torque Down UDC ON or OFF
Tumble generated valve output signal TGV Output ON or OFF
Tumble generated valve drive signal TGV Drive OPEN or CLOSERemarks Display Unit of measure