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 2125 of 2870
EN(H4DOTC 2.5)-101
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK SENSOR OUTPUT.
1) Turn the ignition switch to ON.
2) Measure the voltage between ECM con-
nector and terminal.
Connector & terminal
(B136) No. 29 (+) — (B136) No. 35 (
−):
3) Check the voltage change by shaking the
harness and connector of ECM, engine har-
ness connector and electronic throttle control
connector.Is the voltage more than 0.4 V? Go to step 2.Go to step 3.
2 CHECK POOR CONTACT.
Check the poor contact in connector between
ECM and electronic throttle control.Is there poor contact in con-
nector between ECM and elec-
tronic throttle control?Repair the poor
contact.Temporary poor
contact occurred,
but it is normal at
present.
3 CHECK HARNESS BETWEEN ECM AND
ELECTRONIC THROTTLE CONTROL.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Disconnect the connectors from the elec-
tronic throttle control.
4) Measure the resistance between ECM con-
nector and electronic throttle control connector.
Connector & terminal
(B136) No. 16 — (E57) No. 5:Is the resistance less than 1
Ω?Go to step 4.Repair the open
circuit of harness
connector.
4 CHECK HARNESS BETWEEN ECM AND
ELECTRONIC THROTTLE CONTROL.
Measure the resistance between ECM connec-
tor and chassis ground.
Connector & terminal
(B136) No. 18 — Chassis ground:
(B136) No. 16 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 5.Repair the chassis
short circuit of har-
ness.
5 CHECK POWER SUPPLY OF ELECTRONIC
THROTTLE CONTROL.
1) Connect the ECM connector.
2) Turn the ignition switch to ON.
3) Measure the voltage between electronic
throttle control connector and engine ground.
Connector & terminal
(E57) No. 5 (+) — Engine ground (
−):
4) Check the voltage change by shaking the
harness and connector of ECM and engine
harness connector while monitoring the value
with voltage meter.Is the voltage 4.5 — 5.5 V? Go to step 6.Repair the poor
contact in ECM con-
nector. Replace the
ECM if defective.
41, Engine Con-
trol Module
(ECM).>
6 CHECK SHORT CIRCUIT INSIDE THE ECM.
1) Turn the ignition switch to OFF.
2) Measure the resistance between electronic
throttle control connector and engine ground.
Connector & terminal
(E57) No. 6 — Engine ground:Is the resistance more than 10
Ω?Repair poor con-
tact of electronic
throttle control
connector.
Replace the elec-
tronic throttle con-
trol if defective.Repair the poor
contact in ECM con-
nector. Replace the
ECM if defective.
41, Engine Con-
trol Module
(ECM).>
Page 2127 of 2870
EN(H4DOTC 2.5)-103
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
WIRING DIAGRAM:
Step Check Yes No
1 CHECK SENSOR OUTPUT.
1) Turn the ignition switch to ON.
2) Read the data of main throttle sensor signal
using Subaru Select Monitor.
3) Check the voltage change by shaking the har-
ness and connector of ECM, engine harness con-
nector and electronic throttle control connector.Is the voltage less than 4.63
V?Go to step 2.Go to step 3.
EN-02364
B317
34
12
B22
125678
131415169101112
34
17181920
B21
123
4
56
78
9
1011 12
1314 15 16
B83
1
23456
B135
567
82 1
94 3
10
24 22 23 2511 12 13 14 15
26 27
2816 17 18 19
20 21
29 30 31 32 33 34 35
B:
B35D6
B135 B: C:
D4 D3
C18
B1 C35
D1 B4
D2
SBF-5
2
1
3
4
E
E57
3
6 4
1
2 2
3
15
16
E
5
EE
B137 D:ECM B309
B136
B122
1
E2 B21
E3 B22 B317
E56B47 35
2 1
4 3
D5C16C29
19122018
MAIN RELAYBATTERY
ELECTRONIC
THROTTLE
CONTROL ELECTRONIC
THROTTLE
CONTROL
RELAY
B83
B122
123456783412
56
B47
B137
567
82 1
94 3
10
22 23 11 12 13 14 15
24 25
2616 17
18 19 20 21
27 28 29 30 31
D:
B136
56
782 1
94 3
10
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35
C:
B309
34
12
E57
Page 2128 of 2870
EN(H4DOTC 2.5)-104
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
2 CHECK POOR CONTACT.
Check the poor contact in connector between
ECM and electronic throttle control.Is there poor contact in con-
nector between ECM and elec-
tronic throttle control?Repair the poor
contact.Temporary poor
contact occurred,
but it is normal at
present.
3 CHECK HARNESS BETWEEN ECM AND
ELECTRONIC THROTTLE CONTROL.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Disconnect the connectors from the elec-
tronic throttle control.
4) Measure the resistance between ECM con-
nector and electronic throttle control connector.
Connector & terminal
(B136) No. 18 — (E57) No. 6:
(B136) No. 35 — (E57) No. 3:Is the resistance less than 1
Ω?Go to step 4.Repair the open
circuit of harness
connector.
4 CHECK HARNESS BETWEEN ECM AND
ELECTRONIC THROTTLE CONTROL.
1) Connect the ECM connector.
2) Measure the voltage between electronic
throttle control connector and engine ground.
Connector & terminal
(E57) No. 3 — Engine ground:Is the resistance less than 1
Ω?Go to step 5.Repair the poor
contact in ECM
connector. Replace
the ECM if defec-
tive.
41, Engine Con-
trol Module
(ECM).>
5 CHECK HARNESS BETWEEN ECM AND
ELECTRONIC THROTTLE CONTROL.
1) Turn the ignition switch to ON.
2) Measure the voltage between electronic
throttle control connector and engine ground.
Connector & terminal
(E57) No. 5 (+) — Engine ground (
−):
3) Check the voltage change by shaking the
harness and connector of ECM and engine
harness connector while monitoring the value
with voltage meter.Is the voltage more than 10 V? Go to step 6.Repair battery
short circuit in har-
ness between
ECM connector
and electronic
throttle control
connector.
6 CHECK SENSOR OUTPUT POWER SUP-
PLY.
1) Measure the voltage between electronic
throttle control connector and engine ground.
Connector & terminal
(E57) No. 6 (+) — Engine ground (
−):
2) Check the voltage change by shaking the
harness and connector of ECM and engine
harness connector while monitoring the value
with voltage meter.Is the voltage less than 10 V? Go to step 7.Repair battery
short circuit in har-
ness between
ECM connector
and electronic
throttle control
connector.
7 CHECK HARNESS BETWEEN ECM AND
ELECTRONIC THROTTLE CONTROL.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Measure the resistance between ECM con-
nectors.
Connector & terminal
(B136) No. 18 — (B136) No. 16:Is the resistance more than 1
MΩ?Repair poor contact
in harness. Repair
the electronic throt-
tle control.Repair short circuit
to sensor power
supply. Step Check Yes No
Page 2130 of 2870
EN(H4DOTC 2.5)-106
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK HARNESS BETWEEN ECM AND
FRONT OXYGEN (A/F) SENSOR CONNEC-
TOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM and
front oxygen (A/F) sensor connector.
3) Measure the resistance of harness between
ECM and front oxygen (A/F) sensor connector.
Connector & terminal
(B134) No. 26 — Chassis ground:
(B134) No. 33 — Chassis ground:Is the resistance more than 1
MΩ?Replace the front
oxygen (A/F) sen-
sor.
36, Front Oxygen
(A/F) Sensor.>Repair ground
short circuit in har-
ness between
ECM and front
oxygen (A/F) sen-
sor connector.
Page 2132 of 2870
EN(H4DOTC 2.5)-108
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK HARNESS BETWEEN ECM AND
FRONT OXYGEN (A/F) SENSOR CONNEC-
TOR.
1) Turn the ignition switch to ON.
2) Disconnect the connector from front oxygen
(A/F) sensor.
3) Measure the voltage of harness between
ECM connector and chassis ground.
Connector & terminal
(B134) No. 26 (+) — Chassis ground (
−):
(B134) No. 33 (+) — Chassis ground (
−):Is the voltage more than 8 V? Replace the front
oxygen (A/F) sen-
sor.
36, Front Oxygen
(A/F) Sensor.>Repair battery
short circuit in har-
ness between
ECM and front
oxygen (A/F) sen-
sor connector.
Page 2134 of 2870
EN(H4DOTC 2.5)-110
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK HARNESS BETWEEN ECM AND
FRONT OXYGEN (A/F) SENSOR CONNEC-
TOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM and
front oxygen (A/F) sensor connector.
3) Measure the resistance of harness between
ECM and front oxygen (A/F) sensor connector.
Connector & terminal
(B134) No. 26 — (B262) No. 3:
(B134) No. 33 — (B262) No. 4:Is the resistance less than 1
Ω?Replace the front
oxygen (A/F) sen-
sor.
36, Front Oxygen
(A/F) Sensor.>Repair open circuit
in harness between
ECM and front oxy-
gen (A/F) sensor
connector.
Page 2136 of 2870
EN(H4DOTC 2.5)-112
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
2 CHECK REAR OXYGEN SENSOR DATA.
1) Warm-up the engine until engine coolant
temperature is above 70°C (158°F), and keep
the engine speed at 2,000 rpm to 3,000 rpm for
two minutes.
2) Read the data of rear oxygen (A/F) sensor
signal using Subaru Select Monitor or OBD-II
general scan tool.
N
OTE:
Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”.
OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.Does the value fluctuate? Go to step 6.Go to step 3.
3 CHECK REAR OXYGEN SENSOR DATA.
Read the data of rear oxygen (A/F) sensor sig-
nal using Subaru Select Monitor or OBD-II
general scan tool.Is the voltage 0.2 — 0.4 V? Go to step 4.Replace the rear
oxygen sensor.
38, Rear Oxygen
Sensor.>
4 CHECK HARNESS BETWEEN ECM AND
REAR OXYGEN SENSOR CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM and
rear oxygen sensor.
3) Measure the resistance in harness between
ECM and rear oxygen sensor connector.
Connector & terminal
(B137) No. 25 — (T6) No. 4:Is the resistance more than 3
Ω?Repair open circuit
in harness between
ECM and rear oxy-
gen sensor connec-
tor.Go to step 5.
5 CHECK HARNESS BETWEEN REAR OXY-
GEN SENSOR AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from rear oxygen
sensor.
3) Turn the ignition switch to ON.
4) Measure the voltage between rear oxygen
sensor harness connector and chassis ground.
Connector & terminal
(T6) No. 4 (+) — Chassis ground (
−):Is the voltage more than 0.2 V? Replace the rear
oxygen sensor.
38, Rear Oxygen
Sensor.>Repair the har-
ness and connec-
tor.
NOTE:
In this case repair
the following:
Open circuit in
harness between
rear oxygen sen-
sor and ECM con-
nector
Poor contact in
rear oxygen sen-
sor connector
Poor contact in
ECM connector
6 CHECK EXHAUST SYSTEM.
Check exhaust system parts.
N
OTE:
Check the following items:
Loose part of exhaust system and incom-
plete installation
Damage (crack, hole etc.) of parts
Looseness and ill fitting of parts between front
oxygen (A/F) sensor and rear oxygen sensorIs there a fault in exhaust sys-
tem?Repair or replace
the faulty par t.Replace the rear
oxygen sensor.
38, Rear Oxygen
Sensor.> Step Check Yes No
Page 2138 of 2870
EN(H4DOTC 2.5)-114
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
2 CHECK REAR OXYGEN SENSOR DATA.
1) Warm-up the engine until engine coolant
temperature is above 70°C (158°F), and keep
the engine speed at 2,000 rpm to 3,000 rpm for
two minutes.
2) Read the data of rear oxygen (A/F) sensor
signal using Subaru Select Monitor or OBD-II
general scan tool.
N
OTE:
Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”.
OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.Does the value fluctuate? Go to step 6.Go to step 3.
3 CHECK REAR OXYGEN SENSOR DATA.
Read the data of rear oxygen (A/F) sensor sig-
nal using Subaru Select Monitor or OBD-II
general scan tool.Is the voltage 0.2 — 0.4 V? Go to step 4.Replace the rear
oxygen sensor.
38, Rear Oxygen
Sensor.>
4 CHECK HARNESS BETWEEN ECM AND
REAR OXYGEN SENSOR CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM and
rear oxygen sensor.
3) Measure the resistance in harness between
ECM and rear oxygen sensor connector.
Connector & terminal
(B137) No. 25 — (T6) No. 4:Is the resistance more than 3
Ω?Repair open circuit
in harness between
ECM and rear oxy-
gen sensor connec-
tor.Go to step 5.
5 CHECK HARNESS BETWEEN REAR OXY-
GEN SENSOR AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from rear oxygen
sensor.
3) Turn the ignition switch to ON.
4) Measure the voltage between rear oxygen
sensor harness connector and chassis ground.
Connector & terminal
(T6) No. 4 (+) — Chassis ground (
−):Is the voltage more than 0.2 V? Replace the rear
oxygen sensor.
38, Rear Oxygen
Sensor.>Repair the harness
and connector.
N
OTE:
In this case repair
the following:
Open circuit in
harness between
rear oxygen sen-
sor and ECM con-
nector
Poor contact in
rear oxygen sen-
sor connector
Poor contact in
ECM connector
6 CHECK EXHAUST SYSTEM.
Check exhaust system parts.
N
OTE:
Check the following items:
Loose part of exhaust system and incom-
plete installation
Damage (crack, hole etc.) of parts
Looseness and ill fitting of parts between
front oxygen (A/F) sensor and rear oxygen
sensorIs there a fault in exhaust sys-
tem?Repair or replace
the faulty par t.Replace the rear
oxygen sensor.
38, Rear Oxygen
Sensor.> Step Check Yes No
Page 2139 of 2870
EN(H4DOTC 2.5)-115
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
T: DTC P0171 SYSTEM TOO LEAN (BANK 1)
NOTE:
For diagnostic procedure, refer to DTC P0172.
U: DTC P0172 SYSTEM TOO RICH (BANK 1)
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode
Step Check Yes No
1 CHECK EXHAUST SYSTEM.Are there holes or loose bolts
on exhaust system?Repair exhaust
system.Go to step 2.
2 CHECK AIR INTAKE SYSTEM.Are there holes, loose bolts or
disconnection of hose on air
intake system?Repair air intake
system.Go to step 3.
3 CHECK FUEL PRESSURE.
Warning:
Place “NO FIRE” signs near the working
area.
Be careful not to spill fuel.
1) Release the fuel pressure.
(1) Disconnect the connector from fuel
pump relay.
(2) Start the engine and run it until it stalls.
(3) After the engine stalls, crank it for five
more seconds.
(4) Turn the ignition switch to OFF.
2) Connect the connector to fuel pump relay.
3) Disconnect the fuel delivery hose from fuel
filter, and connect the fuel pressure gauge.
4) Install the fuel filler cap.
5) Start the engine and idle while gear posi-
tion is neutral.
6) Measure the fuel pressure while discon-
necting pressure regulator vacuum hose from
intake manifold.
Warning:
Release fuel pressure before removing the
fuel pressure gauge.
N
OTE:
If fuel pressure does not increase, squeeze the
fuel return hose 2 to 3 times, then measure fuel
pressure again.Is measured value 284 — 314
kPa (2.9 — 3.2 kg/cm
2, 41 —
46 psi)?Go to step 4.Repair the follow-
ing items.
Fuel pressure is
too high:
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line
Page 2140 of 2870
EN(H4DOTC 2.5)-116
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
4 CHECK FUEL PRESSURE.
After connecting the pressure regulator vac-
uum hose, measure fuel pressure.
Warning:
Release fuel pressure before removing the
fuel pressure gauge.
N
OTE:
If fuel pressure does not increase, squeeze
fuel return hose 2 to 3 times, then measure
fuel pressure again.
If out of specification as measured at this
step, check or replace pressure regulator and
pressure regulator vacuum hose.Is measured value 206 — 235
kPa (2.1 — 2.4 kg/cm
2, 30 —
34 psi)?Go to step 5.Repair the follow-
ing items.
Fuel pressure is
too high:
Faulty pres-
sure regulator
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Faulty pres-
sure regulator
Improper fuel
pump discharge
Clogged fuel
supply line
5 CHECK ENGINE COOLANT TEMPERATURE
SENSOR.
1) Start the engine and warm-up completely.
2) Read the data of engine coolant tempera-
ture sensor signal using Subaru Select Monitor
or the OBD-II general scan tool.
NOTE:
Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”.
OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.Is engine coolant temperature
more than 60°C (140°F)?Go to step 6.Replace the
engine coolant
temperature sen-
sor.
26, Engine Cool-
ant Temperature
Sensor.>
6 CHECK MASS AIR FLOW AND INTAKE AIR
TEMPERATURE SENSOR
1) Start and warm-up the engine until engine
coolant temperature is greater than 60°C
(140°F).
2) Place the shift lever in neutral position.
3) Turn the A/C switch to OFF.
4) Turn all accessory switches to OFF.
5) Read the data of mass air flow and intake
air temperature sensor signal using Subaru
Select Monitor or the OBD-II general scan tool.
N
OTE:
Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”.
OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.Is the measured value within
the following?
Ignition ON: 73.3 — 106.6 kPa
(550 — 800 mmHg, 21.65 —
31.50 inHg) Idling: 24.0 — 41.3
kPa (180 — 310 mmHg, 7.09
— 12.20 inHg)Go to step 7.Replace the mass
air flow and intake
air temperature
sensor.
30, Mass Air Flow
and Intake Air
Temperature Sen-
sor.> Step Check Yes No