ignition 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 1272 of 2870
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 (B135) No. 25 (+) — 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:
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”.
by shaking the ECM harness
and connector?
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.
NOTE:
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
(B135) No. 25 (+) — 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) and ECM connector.
3) Measure the resistance between ECM and
chassis ground.Connector & terminal (B135) No. 25 — Chassis ground: Is the resistance more than 1
M
Ω? 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 (B135) No. 25 — (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.
NOTE:
In this case repair
the following:
Poor contact in
coupling connector
EN(H4SO)-174
Page 1273 of 2870
EN(H4SO)-175
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 1274 of 2870
EN(H4SO)-176
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AS: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:
R59R58
R57
R15
B38i3
B98R2
B10
C1 B9
25
3
5
i10 B :
i11 C :B135ECM
EE
E
IGNITION
SWITCH
SBF-4SBF-14
COMBINATION
METERSBF-1
B72
14
FUEL SUB
LEVEL SENSOR
FUEL SUB
METER UNIT
FUEL LEVEL
SENSOR1
2
BATTERY
B38
i3
B38
i320E2
B211528
LHD
LHDRHD
RHDLHD
LHDRHD
RHD
2
16
B38i3
LHD
LHDRHD
RHD
4 3
B99R3
B38i3
LHD
LHDRHD
RHD
16
5
B37i2
EN-02393
2
3
B135
B72
R15R59i10R58
3412
13
456212123456789101112131415161718192021222324252627282930
567
82 1
94
310
24 22 23 251112131415
26 27
281617181920 21
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
25
i3
B99
12345678
i11
34 12 8567910
B37
34 12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 24567
B:
C:
B98
123
4
56
78
9
1011 12
1314 15 16
B21
Page 1275 of 2870
EN(H4SO)-177
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
(B135) No. 25 (+) — Chassis ground (
−):Is the voltage more than 4.75
V?Go to step 3.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
fuel pump connec-
tor
Poor contact in
coupling connector
3 CHECK INPUT VOLTAGE OF ECM.
1) Turn the ignition switch to OFF.
2) Disconnect the combination meter connec-
tor (i11) and ECM connector.
3) Turn the ignition switch to ON.
4) Measure the voltage of harness between
ECM and chassis ground.
Connector & terminal
(B135) No. 25 (+) — Chassis ground (
−):Is the voltage more than 4.75
V?Go to step 4.Repair battery
short circuit
between ECM and
combination meter
connector.
4 CHECK HARNESS BETWEEN ECM AND
FUEL TANK CORD.
1) Turn the ignition switch to OFF.
2) Separate fuel tank cord connector (R57)
and rear wiring harness connector (R15).
3) Measure the resistance between ECM and
fuel tank cord.
Connector & terminal
(B135) No. 25 — (R15) No. 2:Is the resistance less than 5
Ω?Go to step 5.Repair open circuit
between ECM and
fuel tank cord.
5 CHECK HARNESS BETWEEN FUEL TANK
CORD AND CHASSIS GROUND.
Measure the resistance between fuel tank cord
and chassis ground.
Connector & terminal
(R15) No. 3 — Chassis ground:Is the resistance less than 5
Ω?Go to step 6.Repair open circuit
between fuel tank
cord and chassis
ground.
N
OTE:
In this case repair
the following:
Poor contact in
coupling connec-
tor.
6 CHECK FUEL TANK CORD.
1) Disconnect the connector from fuel level
sensor.
2) Measure the resistance between fuel level
sensor and coupler connector.
Connector & terminal
(R57) No. 3 — (R58) No. 5:Is the resistance less than 10
Ω?Go to step 7.Repair open circuit
between coupling
connector and fuel
level sensor.
Page 1277 of 2870
EN(H4SO)-179
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AT:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
WIRING DIAGRAM:
R59R58
R57
R15
B38i3
B98R2
B10
C1 B9
25
3
5
i10 B :
i11 C :B135ECM
EE
E
IGNITION
SWITCH
SBF-4SBF-14
COMBINATION
METERSBF-1
B72
14
FUEL SUB
LEVEL SENSOR
FUEL SUB
METER UNIT
FUEL LEVEL
SENSOR1
2
BATTERY
B38
i3
B38
i320E2
B211528
LHD
LHDRHD
RHDLHD
LHDRHD
RHD
2
16
B38i3
LHD
LHDRHD
RHD
4 3
B99R3
B38i3
LHD
LHDRHD
RHD
16
5
B37i2
EN-02393
2
3
B135
B72
R15R59i10R58
3412
13
456212123456789101112131415161718192021222324252627282930
567
82 1
94
310
24 22 23 251112131415
26 27
281617181920 21
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
25
i3
B99
12345678
i11
34 12 8567910
B37
34 12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 24567
B:
C:
B98
123
4
56
78
9
1011 12
1314 15 16
B21
Page 1280 of 2870
EN(H4SO)-182
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
WIRING DIAGRAM:
EN-02394
No.16
No.17
EE
SBF-4
SBF-1
F17
B134 ECM
14
13F16
F16B72F2 : LHDF27
F17
3412
1
2
SUB FAN
MOTOR
M
1
2
MAIN FAN
MOTOR
M
BATTERY
IGNITION
SWITCHB72
41
21
1234 5678910 11 12 13 14 15 16 17 18 19 20
B134
1234567891011121314151617181920212223242526272829303132333435
3132333435
36
56789
1011121314
1516171819
2021222324
2526272829
1230
34
20A
F27 FAN
MODE
RELAY
AIR CONDITIONING RELAY HOLDER
MAIN
FAN
RELAY-1 SUB
FAN
RELAY
20A
29
25
27
28
30
34
32
317
5
9
2
1
4
3 8 6
B100F2
LHD MODEL : 10
RHD MODEL : 71
LHD MODEL : 11
RHD MODEL : 19
2
*
*
1*
2*
F2 : RHD
12345 678910
11
1219 20 21
13 14 151617
18 22
Page 1283 of 2870
EN(H4SO)-185
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AW:DTC P0503 VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
WIRING DIAGRAM:
EN-02395
i10
BATTERY
12
10
ECM COMBINATION
METER
VEHICLE
SPEED
SENSOR
3
12
B17
B137
17
TCMB56
IGNITION
RELAY
No. 5
B225
B21
E216
MTATB17
123
B21
123
4
56
78
9
1011 12
1314 15 16B62
B:
B56
1234
10 11 12
19 20 21135614 1578916 17 18
22 23 24
112
B225
10111213
1415161718
1920212223
2425262728
2930313233
3435363738
12
934
56
78
i10
123456789101112131415161718192021222324252627282930
B37
34 12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 24567
F45
B137
4
1
53
2618 15 167891011
17 19
20121314
F45
B38i3
B37i2
18
LHD
LHDRHD
RHD
RHD
RHD
LHDLHD
7B38
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
25
C:
*
1*
1 LHD MODEL : 9
RHD MODEL : 37*
2 LHD MODEL : 10
RHD MODEL : 38*
12345678910111213141516
B:C:
Page 1284 of 2870
EN(H4SO)-186
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 DTC P0720 ON DISPLAY.Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC P0720?Check front vehi-
cle speed sensor
signal circuit.
DTC 33 FRONT
VEHICLE SPEED
SENSOR, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>Go to step 3.
3 CHECK SPEEDOMETER OPERATION IN
COMBINATION METER.Does speedometer operate
normally?Go to step 4.Check speedome-
ter and vehicle
speed sensor.
Speed Sensor.>
Speed Sensor.>
Turbine Speed
Sensor.>
4 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
(B137) No. 10 — (i10) No. 12:Is the resistance less than 10
Ω?Repair the poor
contact in ECM
connector.Repair harness
and connector.
NOTE:
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 1286 of 2870
EN(H4SO)-188
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).>
N
OTE:
In this case, it is not
necessary to in-
spect DTC P0506.Go to step 2.
2 CHECK AIR BY-PASS LINE.
1) Turn the ignition switch to OFF.
2) Remove the idle air control solenoid valve
from the throttle body.
3) Remove the throttle body to intake mani-
fold.
4) Using an air gun, force air into the idle air
control solenoid valve installation area. Con-
firm that forced air subsequently escapes from
throttle body.Does air flow out? Replace the idle
air control solenoid
valve.
INSTALLATION,
Idle Air Control
Solenoid Valve.>Replace the throt-
tle body.
INSTALLATION,
Throttle Body.>
Page 1288 of 2870
EN(H4SO)-190
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).>
N
OTE:
In this case, it is not
necessary to in-
spect DTC P0507.Go to step 2.
2 CHECK AIR INTAKE SYSTEM.
1) Turn the ignition switch to ON.
2) Start and idle the engine.
3) Check the following items:
Loose installation of intake manifold, idle air
control solenoid valve and throttle body
Cracks of intake manifold gasket, idle air
control solenoid valve gasket and throttle body
gasket
Disconnections of vacuum hosesIs there any fault in air intake
system?Repair air suction
and leaks.Go to step 3.
3 CHECK THROTTLE CABLE.Is the free play of throttle cable
appropriate?Go to step 4.Adjust throttle
cable.
INSTALLATION,
Accelerator Con-
trol Cable.>
4 CHECK AIR BY-PASS LINE.
1) Turn the ignition switch to OFF.
2) Remove the idle air control solenoid valve
from the throttle body.
3) Confirm that there are no foreign particles
in air by-pass line.Are foreign particles in air by-
pass line?Remove foreign
particles from air
by-pass line.Replace the idle
air control solenoid
valve.
INSTALLATION,
Idle Air Control
Solenoid Valve.>