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 1788 of 2870
EN(H4DOTC)-155
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
5 CHECK HARNESS BETWEEN FUEL PUMP
CONTROL UNIT AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Measure the resistance in harness
between fuel pump control unit and ECM con-
nector.
Connector & terminal
(R122) No. 8 — (B135) No. 27:
(R122) No. 9 — (B137) No. 28:Is the resistance less than 1
Ω?Go to step 6.Repair the har-
ness and connec-
tor.
N
OTE:
In this case repair
the following:
Open circuit
between fuel pump
control unit and
ECM.
Poor contact in
fuel pump control
unit and ECM con-
nector
6 CHECK HARNESS BETWEEN FUEL PUMP
CONTROL UNIT AND ECM CONNECTOR.
Measure the resistance of harness between
fuel pump control unit and chassis ground.
Connector & terminal
(R122) No. 8 — Chassis ground:
(R122) No. 9 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 7.Repair the ground
short circuit
between fuel pump
control unit and
ECM.
7 CHECK POOR CONTACT.
Check poor contact in ECM and fuel pump
control unit connector.Is there poor contact in ECM
and fuel pump control unit con-
nector?Repair the poor
contact in ECM
and fuel pump
control unit.Go to step 8.
8 CHECK EXPERIENCE OF OUT OF GAS.Have the vehicle been out of
gas before?Complete the
diagnosis.
N
OTE:
DTC may be re-
corded due to the
idle running of fuel
pump at out of gas.Replace the fuel
pump control unit.
Fuel Pump Control
Unit.> Step Check Yes No
Page 1792 of 2870
EN(H4DOTC)-159
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. 32 (+) — 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 WASTEGATE
CONTROL SOLENOID VALVE AND ECM
CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connectors from wastegate
control solenoid valve and ECM.
3) Measure the resistance in harness
between wastegate control solenoid valve con-
nector and engine ground.
Connector & terminal
(B127) No. 1 — Engine ground:Is the resistance less than 10
Ω?Repair ground
short circuit in har-
ness between
ECM and waste-
gate control sole-
noid valve
connector.Go to step 3.
3 CHECK HARNESS BETWEEN WASTEGATE
CONTROL SOLENOID VALVE AND ECM
CONNECTOR.
Measure the resistance of harness between
wastegate control solenoid valve and ECM.
Connector & terminal
(B134) No. 32 — (B127) No. 1:Is the resistance less than 1
Ω?Go to step 4.Repair open circuit
in harness
between ECM and
wastegate control
solenoid valve
connector.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
ECM and waste-
gate control sole-
noid valve
connector
4 CHECK WASTEGATE CONTROL SOLE-
NOID VALVE.
1) Remove the wastegate control solenoid
valve.
2) Measure the resistance between wastegate
control solenoid valve terminals.
Te r m i n a l s
No. 1 — No. 2:Is the resistance 30 — 34 Ω? Go to step 5.Replace the
wastegate control
solenoid valve.
Wastegate Con-
trol Solenoid Valve
Assembly.>
5 CHECK POWER SUPPLY TO WASTEGATE
CONTROL SOLENOID VALVE.
1) Turn the ignition switch to ON.
2) Measure the voltage between wastegate
control solenoid valve and engine ground.
Connector & terminal
(B127) No. 2 (+) — Engine ground (
−):Is the voltage more than 10 V? Go to step 6.Repair open circuit
in harness
between main
relay and waste-
gate control sole-
noid valve
connector.
6 CHECK POOR CONTACT.
Check poor contact in wastegate control sole-
noid valve connector.Is there poor contact in waste-
gate control solenoid valve
connector?Repair poor con-
tact in wastegate
control solenoid
valve connector.Contact the SUB-
ARU dealer.
N
OTE:
Inspection by DTM
is required, because
probable cause is
deterioration of mul-
tiple parts.
Page 1794 of 2870
EN(H4DOTC)-161
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. 32 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 3.Go to step 2.
2 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).>
3 CHECK HARNESS BETWEEN WASTEGATE
CONTROL SOLENOID VALVE AND ECM
CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from wastegate
control solenoid valve.
3) Turn the ignition switch to ON.
4) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B134) No. 32 (+) — Chassis ground (
−):Is the voltage more than 10 V? Repair battery
short circuit in har-
ness between
ECM and waste-
gate control sole-
noid valve
connector.After
repair, replace the
ECM.
Engine Control
Module (ECM).>Go to step 4.
4 CHECK WASTEGATE CONTROL SOLE-
NOID VALVE.
1) Turn the ignition switch to OFF.
2) Measure the resistance between wastegate
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
wastegate control
solenoid valve and
ECM.
Wastegate Con-
trol Solenoid Valve
Assembly.>
50, Engine Con-
trol Module
(ECM).>Go to step 5.
5 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 1799 of 2870
EN(H4DOTC)-166
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).>Go to step 2.
2 CHECK OUTPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.
2) Measure the voltage between ECM con-
nector and chassis ground on faulty cylinders.
Connector & terminal
#1 (B136) No. 6 (+) — Chassis ground (
−):
#2 (B136 No. 5 (+) — Chassis ground (
−):
#3 (B136 No. 4 (+) — Chassis ground (
−):
#4 (B136 No. 3 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 7.Go to step 3.
3 CHECK HARNESS BETWEEN FUEL INJEC-
TOR AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from fuel injector
on faulty cylinder.
3) Disconnect the connector from ECM.
4) Measure the voltage between ECM con-
nector and engine ground on faulty cylinders.
Connector & terminal
#1 (E5) No. 1 — Engine ground:
#2 (E16) No. 1 — Engine ground:
#3 (E6) No. 1 — Engine ground:
#4 (E17) No. 1 — Engine ground:Is the resistance more than 1
MΩ?Go to step 4.Repair ground
short circuit in har-
ness between fuel
injector and ECM
connector.
4 CHECK HARNESS BETWEEN FUEL INJEC-
TOR AND ECM CONNECTOR.
Measure the resistance of harness connector
between ECM connector and fuel injector on
faulty cylinders.
Connector & terminal
#1 (B136) No. 6 — (E5) No. 1:
#2 (B136) No. 5 — (E16) No. 1:
#3 (B136) No. 4 — (E6) No. 1:
#4 (B136) No. 3 — (E17) No. 1:Is the resistance less than 1
Ω?Go to step 5.Repair the har-
ness and connec-
tor.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
5 CHECK FUEL INJECTOR.
Measure the resistance between fuel injector
terminals on faulty cylinder.
Te r m i n a l s
No. 1 — No. 2:Is the resistance 5 — 20 Ω? Go to step 6.Replace the faulty
fuel injector.
38, Fuel Injector.>
Page 1800 of 2870
EN(H4DOTC)-167
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
6 CHECK POWER SUPPLY LINE.
1) Turn the ignition switch to ON.
2) Measure the voltage between fuel injector
and engine ground on faulty cylinders.
Connector & terminal
#1 (E5) No. 2 (+) — Engine ground (
−):
#2 (E16) No. 2 (+) — Engine ground (
−):
#3 (E6) No. 2 (+) — Engine ground (
−):
#4 (E17) No. 2 (+) — Engine ground (
−):Is the voltage more than 10 V? Repair poor con-
tact in all connec-
tors in fuel injector
circuit.Repair the har-
ness and connec-
tor.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
main relay and fuel
injector connector
on faulty cylinders
Poor contact in
coupling connector
Poor contact in
main relay connec-
tor
Poor contact in
fuel injector con-
nector on faulty
cylinders
7 CHECK HARNESS BETWEEN FUEL INJEC-
TOR AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from fuel injector
on faulty cylinder.
3) Turn the ignition switch to ON.
4) Measure the voltage between ECM con-
nector and chassis ground on faulty cylinders.
Connector & terminal
#1 (B136) No. 6 (+) — Chassis ground (
−):
#2 (B136 No. 5 (+) — Chassis ground (
−):
#3 (B136 No. 4 (+) — Chassis ground (
−):
#4 (B136 No. 3 (+) — Chassis ground (
−):Is the voltage more than 10 V? Repair battery
short circuit in har-
ness between
ECM and fuel
injector.After
repair, replace the
ECM.
Engine Control
Module (ECM).>Go to step 8.
8 CHECK FUEL INJECTOR.
1) Turn the ignition switch to OFF.
2) Measure the resistance between fuel injec-
tor terminals on faulty cylinder.
Te r m i n a l s
No. 1 — No. 2:Is the resistance less than 1
Ω?Replace the faulty
fuel injector and
ECM.
Fuel Injector.>
Engine Control
Module (ECM).>Go to step 9.
9 CHECK INSTALLATION OF CAMSHAFT PO-
SITION SENSOR/CRANKSHAFT POSITION
SENSOR.Is the installation of camshaft
position sensor or crankshaft
position sensor loosened?Tighten camshaft
position sensor or
crankshaft posi-
tion sensor.Go to step 10.
10 CHECK CRANK SPROCKET.
Remove the timing belt cover.Is the crank sprocket rusted or
does it have broken teeth?Replace the crank
sprocket.
Crank Sprocket.>Go to step 11.
11 CHECK INSTALLATION CONDITION OF
TIMING BELT.
Turn the crankshaft, and align alignment mark
on crank sprocket with alignment mark on cyl-
inder block.Is the timing belt dislocated
from its proper position?Repair installation
condition of timing
belt.
Timing Belt
Assembly.>Go to step 12. Step Check Yes No
Page 1801 of 2870
EN(H4DOTC)-168
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
12 CHECK FUEL LEVEL.Is the fuel meter indication
higher than the “Lower” level?Go to step 13.Replenish fuel so
fuel meter indica-
tion is higher than
the “Lower”
level.After replen-
ishing fuel, Go to
step 13.
13 CHECK STATUS OF MALFUNCTION INDI-
CATOR LIGHT.
1) Clear the memory using Subaru Select
Monitor.
2) Start the engine, and drive the vehicle more
than 10 minutes.Does the malfunction indicator
light illuminate or blink?Go to step 15.Go to step 14.
14 CHECK CAUSE OF MISFIRE DIAGNOSED.Was the cause of misfire diag-
nosed when the engine is run-
ning?Finish diagnostics
operation, if the
engine has no
abnormality.Repair the poor
contact.
N
OTE:
In this case repair
the following:
Poor contact in
ignition coil con-
nector
Poor contact in
fuel injector con-
nector on faulty
cylinders
Poor contact in
ECM connector.
Poor contact in
coupling connector
15 CHECK AIR INTAKE SYSTEM.Is there any fault in air intake
system?Repair air intake
system.
N
OTE:
Check the follow-
ing items:
Are there air
leaks or air suction
caused by loose or
dislocated nuts
and bolts?
Are there cracks
or any disconnec-
tion of hoses?Go to step 16.
16 CHECK CYLINDER.Is there a fault in that cylinder? Repair or replace
the faulty par t.
N
OTE:
Check the follow-
ing items:
Spark plug
Fuel injector
CompressionGo to DTC P0171
and P0172.
148, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).> Step Check Yes No
Page 1803 of 2870
EN(H4DOTC)-170
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK HARNESS BETWEEN KNOCK SEN-
SOR AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Measure the resistance between ECM har-
ness connector and chassis ground.
Connector & terminal
(B136) No. 25 — Chassis ground:Is the resistance more than
700 kΩ?Go to step 2.Repair the har-
ness and connec-
tor.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
knock sensor con-
nector
Poor contact in
coupling connector
2 CHECK KNOCK SENSOR.
1) Disconnect the connector from knock sen-
sor.
2) Measure the resistance between knock
sensor connector terminal and engine ground.
Te r m i n a l s
No. 2 — Engine ground:Is the resistance more than
700 kΩ?Go to step 3.Repair the har-
ness and connec-
tor.
N
OTE:
In this case repair
the following:
Poor contact in
knock sensor con-
nector
Poor contact in
coupling connector
3 CHECK CONDITION OF KNOCK SENSOR
INSTALLATION.Is the knock sensor installation
bolt tightened securely?Replace the knock
sensor.
Knock Sensor.>Tighten knock sen-
sor installation bolt
securely.
Page 1805 of 2870
EN(H4DOTC)-172
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK HARNESS BETWEEN KNOCK SEN-
SOR AND ECM CONNECTOR.
Measure the resistance of harness between
ECM connector and chassis ground.
Connector & terminal
(B136) No. 25 — Chassis ground:Is the resistance less than 400
kΩ?Go to step 2.Go to step 3.
2 CHECK KNOCK SENSOR.
1) Disconnect the connector from knock sen-
sor.
2) Measure the resistance between knock
sensor connector terminal and engine ground.
Te r m i n a l s
No. 2 — Engine ground:Is the resistance less than 400
kΩ?Replace the knock
sensor.
Knock Sensor.>Repair ground
short circuit in har-
ness between
knock sensor con-
nector and ECM
connector.
N
OTE:
The harness be-
tween both con-
nectors are
shielded.Repair
short circuit in har-
ness covered with
shield.
3 CHECK INPUT SIGNAL FROM ECM.
1) Connect the connectors to ECM and knock
sensor.
2) Turn the ignition switch to ON.
3) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B136) No. 25 (+) — Chassis ground (
−):Is the voltage more than 2 V? Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time.(However,
the possibility of
poor contact still
remains.)
NOTE:
In this case repair
the following:
Poor contact in
knock sensor con-
nector
Poor contact in
ECM connector.
Poor contact in
coupling connectorRepair the poor
contact in ECM
connector.
Page 1807 of 2870
EN(H4DOTC)-174
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK HARNESS BETWEEN CRANK-
SHAFT POSITION SENSOR AND ECM CON-
NECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from the crank-
shaft position sensor.
3) Measure the resistance of harness
between crankshaft position sensor connector
and engine ground.
Connector & terminal
(E10) No. 1 — Engine ground:Is the resistance more than
100 kΩ?Repair the har-
ness and connec-
tor.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
crankshaft posi-
tion sensor and
ECM connector
Poor contact in
ECM connector.
Poor contact in
coupling connectorGo to step 2.
2 CHECK HARNESS BETWEEN CRANK-
SHAFT POSITION SENSOR AND ECM CON-
NECTOR.
Measure the resistance of harness between
crankshaft position sensor connector and
engine ground.
Connector & terminal
(E10) No. 1 — Engine ground:Is the resistance more than 1
MΩ?Go to step 3.Repair ground
short circuit in har-
ness between
crankshaft posi-
tion sensor and
ECM connector.
N
OTE:
The harness be-
tween both con-
nectors are
shielded.Repair
ground short circuit
in harness togeth-
er with shield.
3 CHECK HARNESS BETWEEN CRANK-
SHAFT POSITION SENSOR AND ECM CON-
NECTOR.
Measure the resistance of harness between
crankshaft position sensor connector and
engine ground.
Connector & terminal
(E10) No. 2 — Engine ground:Is the resistance less than 5
Ω?Go to step 4.Repair the har-
ness and connec-
tor.
NOTE:
In this case repair
the following:
Open circuit in
harness between
crankshaft posi-
tion sensor and
ECM connector
Poor contact in
ECM connector.
Poor contact in
coupling connector
4 CHECK CONDITION OF CRANKSHAFT PO-
SITION SENSOR.Is the crankshaft position sen-
sor installation bolt tightened
securely?Go to step 5.Tighten the crank-
shaft position sen-
sor installation bolt
securely.
5 CHECK CRANKSHAFT POSITION SENSOR.
1) Remove the crankshaft position sensor.
2) Measure the resistance between connector
terminals of crankshaft position sensor.
Te r m i n a l s
No. 1 — No. 2:Is the resistance 1 — 4 kΩ? Repair poor con-
tact in crankshaft
position sensor
connector.Replace the crank-
shaft position sen-
sor.
Crankshaft Posi-
tion Sensor.>
Page 1809 of 2870
EN(H4DOTC)-176
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).>Go to step 2.
2 CHECK CONDITION OF CRANKSHAFT PO-
SITION SENSOR.
Turn the ignition switch to OFF.Is the crankshaft position sen-
sor installation bolt tightened
securely?Go to step 3.Tighten the crank-
shaft position sen-
sor installation bolt
securely.
3 CHECK CRANK SPROCKET.
Remove the front belt cover.Are crank sprocket teeth
cracked or damaged?Replace the crank
sprocket.
Crank Sprocket.>Go to step 4.
4 CHECK INSTALLATION CONDITION OF
TIMING BELT.
Turn the crankshaft, and align alignment mark
on crank sprocket with alignment mark on cyl-
inder block.Is the timing belt dislocated
from its proper position?Repair installation
condition of timing
belt.
Timing Belt
Assembly.>Replace the crank-
shaft position sen-
sor.
Crankshaft Posi-
tion Sensor.>