combination meter SUBARU FORESTER 2004 Service Manual PDF
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
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 1276 of 2870
EN(H4SO)-178
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
7 CHECK FUEL TANK CORD.
1) Disconnect the connector from fuel sub
level sensor.
2) Measure the resistance between fuel level
sensor and fuel sub level sensor.
Connector & terminal
(R58) No. 3 — (R59) No. 2:Is the resistance less than 10
Ω?Go to step 8.Repair open circuit
between fuel level
sensor and fuel
sub level sensor.
8 CHECK FUEL TANK CORD.
Measure the resistance between fuel level sen-
sor and coupler connector.
Connector & terminal
(R57) No. 2 — (R59) No. 1:Is the resistance less than 10
Ω?Go to step 9.Repair open circuit
between coupling
connector and fuel
level sensor.
9 CHECK FUEL LEVEL SENSOR.
1) Remove the fuel pump assembly.
2) While moving the fuel level sensor float up
and down, measure resistance between fuel
level sensor terminals.
Te r m i n a l s
No. 3 — No. 5:Is the resistance more than
54.5 Ω?Replace the fuel
level sensor.
Fuel Level Sen-
sor.>Go to step 10.
10 CHECK FUEL SUB LEVEL SENSOR.
1) Remove the fuel sub level sensor.
2) While moving the fuel sub level sensor float
up and down, measure resistance between
fuel sub level sensor terminals.
Te r m i n a l s
No. 1 — No. 2:Is the resistance more than
41.5 Ω?Replace the fuel
sub level sensor.
Fuel Sub Level
Sensor.>Replace the com-
bination meter.
Meter Assembly.> Step Check Yes No
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 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 1566 of 2870
ME(H4DOTC)-106
MECHANICAL
Cylinder Block
2.0 L MODEL
Standard diameter:
A: 92.005 — 92.015 mm (3.6222 — 3.6226 in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222 in)
2.5 L MODEL
Standard diameter:
A: 99.505 — 99.515 mm (3.9175 — 3.9179 in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175 in)
2) How to measure the inner diameter of each cyl-
inder:
Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights
shown in the figure, using a cylinder bore gauge.
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
3) When the piston is to be replaced due to general
or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
4) How to measure the outer diameter of each pis-
ton:
Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
(A) Main journal size mark
(B) Cylinder block (RH)-(LH) combination mark
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark
(F) #4 cylinder bore size mark
ME-00170 #5
#4
#3
#2
#1(A)(B)
(F)
(D)
A BA B
5 45 4
(C) (E)
(A) Piston pin direction
(B) Thrust direction
H1: 10 mm (0.39 in)
H2: 45 mm (1.77 in)
H3: 80 mm (3.15 in)
H4: 115 mm (4.53 in)
ME-00171
(A)
(B)
H2 H1
H3
H4
Page 1637 of 2870
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
Page 1681 of 2870
EN(H4DOTC)-51
ENGINE (DIAGNOSTIC)
Malfunction Indicator Light
B: ACTIVATION OF MALFUNCTION
INDICATOR LIGHT
1) When the ignition switch is turned to ON (engine
off), the malfunction indicator light in the combina-
tion meter illuminates.
NOTE:
If the malfunction indicator light does not illuminate,
perform the diagnosis of malfunction indicator light
circuit or the combination meter circuit.
LIGHT DOES NOT COME ON, Malfunction Indica-
tor Light.>
2) After starting the engine, the malfunction indica-
tor light goes out.If it does not, either the engine or
the emission control system is malfunctioning.3) If the diagnosis system detects a misfire which
could damage the catalyst, the malfunction indica-
tor light will blink at a cycle of 1 Hz.
4) When the ignition switch is turned to ON (engine
off) or to “START” with the test mode connector
connected, the malfunction indicator light blinks at
a cycle of 3 Hz.
(A) Malfunction indicator light
(1) No faulty
(2) Trouble occurs
(3) ON
(4) OFF
(5) Ignition switch ON
(6) Engine start
EN-00335(A)
EN-01679
(1)
(2)
(5)
(6)(3)
(4)
(3)
(4)
(1) ON
(2) OFF
(3) Ignition switch ON
(4) Engine start
(5) Misfire start
(6) 1 second
(1) ON
(2) OFF
(3) Ignition switch ON
(4) 1 second
EN-01680
(2) (1)
(3)
(4)
(5)(6)
EN-01681
(2)(1)
(4)
(3)
Page 1682 of 2870
EN(H4DOTC)-52
ENGINE (DIAGNOSTIC)
Malfunction Indicator Light
C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON
DIAGNOSIS:
The malfunction indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not operate.
WIRING DIAGRAM:
EN-02309
BATTERYIGNITION
SWITCH
SBF-4SBF-1
B72
B72
B38
B134
ECM
i3
E
14
RHD
RHD
A17
B37
i12 A :
i10 B :
i12i10B134
i3
i2
LHD
LHD
5
COMBINATION
METER
3412
123 456
789 121310 11 14
*
16
B38
i3
B37No.14
*LHD : 17
RHD : 13
B9
A1
34
12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 24567219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
25
12345678910111213141516171819202122232425262728293056 7
82 1
94 310
24 22 23 25 11 12 13 14 15
26 27
2816 17
18 19 20 21
33 34 29
32 30 31
A:
Page 1683 of 2870
EN(H4DOTC)-53
ENGINE (DIAGNOSTIC)
Malfunction Indicator Light
Step Check Yes No
1 CHECK OUTPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.
2) Measure the voltage between ECM con-
nector and chassis ground.
Connector & terminal
(B134) No. 17 (+) — Chassis ground (
−):Is the voltage less than 1 V? Go to step 4.Go to step 2.
2 CHECK POOR CONTACT.Does the malfunction indicator
light come on when shaking or
pulling the ECM connector and
harness?Repair the poor
contact in ECM
connector.Go to step 3.
3 CHECK ECM CONNECTOR.Is the ECM connector correctly
connected?Replace the ECM.
Engine Control
Module (ECM).>Repair the con-
nection of ECM
connector.
4 CHECK HARNESS BETWEEN COMBINA-
TION METER AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Remove the combination meter.
3) Disconnect the connector from ECM and
combination meter.
4) Measure the resistance of harness
between ECM and combination meter connec-
tor.
Connector & terminal
(B134) No. 17 — (i12) No. 1:Is the resistance less than 1
Ω?Go to step 5.Repair the har-
ness and connec-
tor.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and combi-
nation meter con-
nector
Poor contact in
coupling connector
5 CHECK POOR CONTACT.
Check poor contact in combination meter con-
nector.Is there poor contact in combi-
nation meter connector?Repair poor con-
tact in combination
meter connector.Go to step 6.
6 CHECK HARNESS BETWEEN COMBINA-
TION METER AND IGNITION SWITCH CON-
NECTOR.
1) Turn the ignition switch to ON.
2) Measure the voltage between combination
meter connector and chassis ground.
Connector & terminal
(i10) No. 9 (+) — Chassis ground (
−):Is the voltage more than 10 V? Replace the board
of combination
meter.
Meter Assembly.>Check the follow-
ing and repair if
necessary.
N
OTE:
Blown out of
fuse (No. 14)
Open or short
circuit in harness
between fuse (No.
14) and battery
terminal
Poor contact in
ignition switch con-
nector