engine SUBARU FORESTER 2004 Service Repair Manual

EN(H4SO)-251
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
CP:DTC P1711 ENGINE TORQUE CONTROL SIGNAL #1 CIRCUIT MALFUNC-
TION
DTC DETECTING CONDITION:
TROUBLE SYMPTOM:
Excessive shift shock
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode ERATION, Clear Memory Mode.> and Inspection Mode tion Mode.>.
WIRING DIAGRAM:
EN-00286
B136
1
ECM
B56TCM
5
B56
1234
10 11 12
19 20 21135614 1578916 17 18
22 23 24
B136
5
2
84
3923 20 211011
221617
24
2512136
261915
14
1
7
18

EN(H4SO)-252
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK INPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.
2) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B136) No. 1 (+) — Chassis ground (
−):Is the voltage more than 4.5 V? Go to step 2.Go to step 4.
2 CHECK INPUT SIGNAL FROM ECM.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(B136) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10 V? Repair battery
short circuit in har-
ness between
ECM and TCM
connector.Go to step 3.
3 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.
FU(H4SO)-44,
Engine Control
Module (ECM).>
4 CHECK HARNESS BETWEEN ECM AND
TCM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM and
TCM.
3) Measure the resistance of harness
between TCM and ECM connector.
Connector & terminal
(B136) No. 1 — (B56) No. 5:Is the resistance less than 1
Ω?Go to step 5.Repair the open
circuit in harness
between ECM and
TCM connector.
5 CHECK HARNESS BETWEEN ECM AND
TCM CONNECTOR.
Measure the resistance of harness between
ECM and chassis ground.
Connector & terminal
(B136) No. 1 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 6.Repair ground
short circuit in har-
ness between
ECM and TCM
connector.
6 CHECK POOR CONTACT.
Check poor contact in TCM connector.Is there poor contact in TCM
connector?Repair poor con-
tact in TCM con-
nector.Replace the TCM.
Transmission Con-
trol Module
(TCM).>

EN(H4SO)-253
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
CQ:DTC P1712 ENGINE TORQUE CONTROL SIGNAL #2 CIRCUIT MALFUNC-
TION
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Excessive shift shock
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode ERATION, Clear Memory Mode.> and Inspection Mode tion Mode.>.
WIRING DIAGRAM:
EN-00287
B136
18
ECM
B56TCM
14
B56
B136
5
2
84
3923 20 211011
221617
24
2512136
261915
14
1
7
18
123410 11 12
19 20 21135614 1578916 17 18
22 23 24

EN(H4SO)-254
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK INPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.
2) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B136) No. 18 (+) — Chassis ground (
−):Is the voltage more than 4.5 V? Go to step 2.Go to step 4.
2 CHECK INPUT SIGNAL FROM ECM.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(B136) No. 18 (+) — Chassis ground (
−):Is the voltage more than 10 V? Repair battery
short circuit in har-
ness between
ECM and TCM
connector.Go to step 3.
3 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.
FU(H4SO)-44,
Engine Control
Module (ECM).>
4 CHECK HARNESS BETWEEN ECM AND
TCM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM and
TCM.
3) Measure the resistance of harness
between TCM and ECM connector.
Connector & terminal
(B136) No. 18 — (B56) No. 14:Is the resistance less than 1
Ω?Go to step 5.Repair the open
circuit in harness
between ECM and
TCM connector.
5 CHECK HARNESS BETWEEN ECM AND
TCM CONNECTOR.
Measure the resistance of harness between
ECM and chassis ground.
Connector & terminal
(B136) No. 18 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 6.Repair ground
short circuit in har-
ness between
ECM and TCM
connector.
6 CHECK POOR CONTACT.
Check poor contact in TCM connector. Is there poor contact in TCM
connector?Repair poor con-
tact in TCM con-
nector.Replace the TCM.
Transmission Con-
trol Module
(TCM).>

EN(H4SO)-255
ENGINE (DIAGNOSTIC)
General Diagnostic Table
20.General Diagnostic Table
A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. eral.>
Symptom Problem parts
1. Engine stalls during idling.1) Idle air control solenoid valve
2) Manifold absolute pressure sensor
3) 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) Idle air control solenoid valve
2) Manifold absolute pressure sensor
3) 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) Throttle position sensor
9) Crankshaft position sensor (*3)
10) Camshaft position sensor (*3)
11) Oxygen sensor
12) Fuel pump and fuel pump relay
3. Engine does not return to idle.1) Idle air control solenoid valve
2) Engine coolant temperature sensor
3) Accelerator cable (*6)
4) Throttle position sensor
5) Manifold absolute pressure sensor
6) Intake air temperature sensor
4. Poor acceleration1) Manifold absolute pressure sensor
2) Intake air temperature sensor
3) Throttle position sensor
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) 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) Throttle position sensor
9) Fuel pump and fuel pump relay

EN(H4SO)-256
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.
*6: Adjust the accelerator cable.
2. AUTOMATIC TRANSMISSION
NOTE:
Check general diagnostics table with non-conformity symptom for automatic transmission. 4AT(H4SO)-2, Basic Diagnostic Procedure.>
6. Surging1) Intake manifold pressure sensor
2) Intake air temperature sensor
3) Manifold absolute pressure sensor
4) Engine coolant temperature sensor (*2)
5) Crankshaft position sensor (*3)
6) Camshaft position sensor (*3)
7) Fuel injection parts (*4)
8) Throttle position sensor
9) Fuel pump and fuel pump relay
7. Spark knock1) Intake manifold pressure sensor
2) Intake air temperature sensor
3) Manifold absolute pressure sensor
4) Engine coolant temperature sensor
5) Knock sensor
6) Fuel injection parts (*4)
7) Fuel pump and fuel pump relay
8. After burning in exhaust system1) Intake manifold pressure sensor
2) Intake air temperature sensor
3) Manifold absolute pressure sensor
4) Engine coolant temperature sensor (*2)
5) Fuel injection parts (*4)
6) Fuel pump and fuel pump relay Symptom Problem parts

FUJI HEAVY INDUSTRIES LTD. G8080GE3
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 2
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.FUEL INJECTION (FUEL SYSTEM) FU(H4DOTC)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC)
INTAKE (INDUCTION) IN(H4DOTC)
MECHANICAL ME(H4DOTC)
EXHAUST EX(H4DOTC)
COOLING CO(H4DOTC)
LUBRICATION LU(H4DOTC)
SPEED CONTROL SYSTEM SP(H4DOTC)
IGNITION IG(H4DOTC)
STARTING/CHARGING SYSTEM SC(H4DOTC)
ENGINE (DIAGNOSTIC) EN(H4DOTC)

FUEL INJECTION (FUEL SYSTEM)
FU(H4DOTC)
Page
1. General Description ....................................................................................2
2. Throttle Body .............................................................................................13
3. Intake Manifold ..........................................................................................14
4. Engine Coolant Temperature Sensor........................................................29
5. Crankshaft Position Sensor.......................................................................30
6. Camshaft Position Sensor.........................................................................31
7. AVCS Camshaft Position Sensor ..............................................................32
8. Knock Sensor ............................................................................................33
9. Throttle Position Sensor ............................................................................34
10. Mass Air Flow and Intake Air Temperature Sensor ..................................35
11. Manifold Absolute Pressure Sensor ..........................................................36
12. Idle Air Control Solenoid Valve .................................................................37
13. Fuel Injector ..............................................................................................38
14. Tumble Generator Valve Assembly ..........................................................42
15. Tumble Generator Valve Actuator.............................................................43
16. Wastegate Control Solenoid Valve Assembly ...........................................44
17. Front Oxygen (A/F) Sensor .......................................................................45
18. Rear Oxygen Sensor.................................................................................47
19. Exhaust Temperature Sensor ...................................................................49
20. Engine Control Module (ECM) ..................................................................50
21. Main Relay ................................................................................................51
22. Fuel Pump Relay.......................................................................................52
23. Fuel Pump Control Unit .............................................................................53
24. Fuel ...........................................................................................................54
25. Fuel Tank ..................................................................................................55
26. Fuel Filler Pipe ..........................................................................................58
27. Fuel Pump .................................................................................................62
28. Fuel Level Sensor .....................................................................................64
29. Fuel Sub Level Sensor ..............................................................................65
30. Fuel Filter ..................................................................................................67
31. Fuel Cut Valve...........................................................................................68
32. Fuel Damper Valve ...................................................................................69
33. Fuel Delivery, Return and Evaporation Lines............................................70
34. Fuel System Trouble in General ...............................................................73

FU(H4DOTC)-13
FUEL INJECTION (FUEL SYSTEM)
Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intercooler. 10, REMOVAL, Intercooler.>
3) Disconnect the connector from the throttle posi-
tion sensor (A) and idle air control solenoid valve
(B) and manifold absolute pressure sensor (C).
4) Disconnect the accelerator cable.
5) Disconnect the engine coolant hoses from throt-
tle body.6) Remove the bolts which secure the throttle body
to intake manifold.B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 16.2 ft-lb)
2) Adjust the accelerator cable play. SP(H4SO)-9, INSTALLATION, Accelerator Control
Cable.>
FU-00009
(A)(B)
(C)
FU-00010
FU-00011
FU-00012
FU-00013

FU(H4DOTC)-15
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(6) Place the power steering pump on right side
wheel apron.
13) Disconnect the emission hose from PCV valve.
14) Disconnect the engine coolant hoses from
throttle body.
15) Disconnect the brake booster hose.16) Disconnect the pressure hose from intake duct.
17) Disconnect the engine harness connectors
from bulkhead harness connectors.
18) Disconnect the connectors from the engine
coolant temperature sensor (A), oil pressure switch
(B) and crankshaft position sensor (C).
FU-00021
FU-00022
FU-00012
FU-00023
FU-00024
FU-00025
FU-02086
(A)
(B)
(C)
FU-00027