relay SUBARU FORESTER 2004 Service Manual PDF

ME(H4SO)-93
MECHANICAL
Engine Trouble in General
3. Low output, hesitation and
poor accelerationEngine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose B
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element A
Fuel line Defective fuel pump and relay B
Clogged fuel line B
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
Improper valve seating B
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Cooling system Overheating C
Over cooling C
Others Malfunction of evaporative emission control system A
4. Surging Engine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element B
Fuel line Defective fuel pump and relay B
Clogged fuel line B
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper engine oil (low viscosity) B
Cooling system Overheating B
Others Malfunction of evaporative emission control system C TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

CO(H4SO)-13
COOLING
Radiator Fan System
2. Radiator Fan System
A: WIRING DIAGRAM
CO-02003
B72 SBF-1
SBF-4
NO.17
NO.18
MAIN FAN MOTOR
(EXCEPT TURBO AT MODEL)
F17
2
1
ET
MAIN
FA N
RELAY-1
FA N
MODE
RELAY31
34
32
30
5
9
7
8
6 SUB
FA N
RELAY A/C RELAY HOLDER
28
25
3
4
27
29
RHD
RHD
RHD
RHDLHD
LHD
LHD
F2
B1001110F2
B100197
2
1
F27
B25
B24
A14
ECM
(NON- TURBO MODEL)B134 A:
A13
NA
F17
F16
21
LHD
RHD
F2(BLACK)
(BLACK) (GRAY)
(GRAY)F2
A/C RELAY HOLDER
F27
12
34
567891110
1312142120
2322243130
333234
1615171819
26252728293536
B:B135
A:
B134
1234567891011121314151617181920212223242526272829303132333435
: : ::
ET
TA
1234 5678910 11 12 13 14 15 16 17 18 19 2012345
678910
11 12 19 20 2113 14 15 16 17 18 22
B135 B:
ECM
(TURBO MODEL)
(BLUE)
(BLUE)
567 2 134
2910
1112131415252416
30
98171819202821222332312627333435
: TURBO MODELTB
: NON-TURBO
MODEL
NA: TURBO AT MODEL
TA
: EXCEPT TURBO
AT MODEL
ET
: KA TURBO MODEL AND
EC,EK TURBO AT MODEL : 30A 1*
1*
1*
: LHD MODEL : (GRAY) 2*
2*
SUB FAN MOTOR
(TURBO AT MODEL)
F16
1
2
MAIN FAN MOTOR
(TURBO AT MODEL)
F17
1
2
SUB FAN MOTOR
(EXCEPT TURBO AT MODEL)
F16
2
1
TA
ET
TA
TA
LHD
TA
ET
ET
TBNA
TB
12
F17
F16TA
:
TA
ET
:
ET
E
EXCEPT KA TURBO MODEL AND
EC,EK TURBO AT MODEL: 20A
IGNITION SWITCH
BATTERY
3412
B72

CO(H4SO)-14
COOLING
Radiator Fan System
B: INSPECTION
DETECTING CONDITION:
 Engine coolant temperature is above 95°C (203°F).
 Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOM:
Radiator main fan and sub fan does not rotate under the above conditions.
Step Check Yes No
1 CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
2) Turn the ignition switch to ON.
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan relay.
N
OTE:
 With Subaru Select Monitor
When checking the compulsory operation of
radiator fan, the radiator main and sub fan
repeat the rotation in order of following: low
speed rotation → high speed rotation → off.
 Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detail procedures. EN(H4SO)-45, Compulsory Valve Operation
Check Mode.>Do the radiator main and sub
fan rotate at low speed?Go to step 2.Go to step 3.
2 CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
2) Turn the ignition switch to ON.
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan relay.
N
OTE:
 With Subaru Select Monitor
When checking the compulsory operation of
radiator fan, the radiator main and sub fan
repeat the rotation in order of following: low
speed rotation → high speed rotation → off.
 Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detail procedures. EN(H4SO)-45, Compulsory Valve Operation
Check Mode.>Do the radiator main and sub
fan rotate at high speed?Radiator main fan
system is okay.Go to step 32.
3 CHECK POWER SUPPLY TO MAIN FAN RE-
LAY.
1) Turn the ignition switch to OFF.
2) Remove the fan relay 1 from A/C relay
holder.
3) Measure the voltage between main fan
relay terminal and chassis ground.
Connector & terminal
(F27) No. 31 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 4.Go to step 5.
4 CHECK POWER SUPPLY TO MAIN FAN RE-
LAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between main fan
relay terminal and chassis ground.
Connector & terminal
(F27) No. 34 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 8.Go to step 7.
5 CHECK FUSE.
1) Remove the fuse from A/C relay holder.
2) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Go to step 6.

CO(H4SO)-15
COOLING
Radiator Fan System
6 CHECK HARNESS OF FUSE TERMINAL
AND MAIN FAN RELAY TERMINAL.
1) Turn the ignition switch to OFF.
2) Measure the resistance between 20 A fuse
terminal and main fan relay terminal.
Te r m i n a l
No. 2 — No. 31:Is the resistance less than 1
Ω?Repair the power
supply line.Repair the open
harness.
7 CHECK FUSE.
1) Turn the ignition switch to OFF
2) Remove the fuse No. 18.
3) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Repair the power
supply line.
8 CHECK MAIN FAN RELAY.
1) Turn the ignition switch to OFF.
2) Measure the resistance between main fan
relay terminals.
Te r m i n a l
No. 30 — No. 31:Is the resistance more than 1
MΩ?Go to step 9.Replace the main
fan relay.
9 CHECK MAIN FAN RELAY.
1) Connect the battery to main fan relay termi-
nals No. 32 and No. 34.
2) Measure the resistance between main fan
relay terminals.
Te r m i n a l
No. 30 — No. 31:Is the resistance less than 1
Ω?Go to step 10.Replace the main
fan relay.
10 CHECK HARNESS BETWEEN MAIN FAN
RELAY TERMINAL AND MAIN FAN MOTOR
CONNECTOR.
1) Disconnect the connector from main fan
motor.
2) Measure the resistance between main fan
relay terminal and main fan motor connector.
Connector & terminal
Turbo AT model
(F17) No. 1 — (F27) No. 30:
Except turbo AT model
(F17) No. 2 — (F27) No. 30:Is the resistance less than 1
Ω?Go to step 11.Repair the open
harness between
main fan relay ter-
minal and main fan
motor connector.
11 CHECK HARNESS BETWEEN MAIN FAN
MOTOR CONNECTOR AND FAN MODE RE-
LAY CONNECTOR.
1) Remove the fan mode relay from A/C relay
holder.
2) Measure the resistance between main fan
motor connector and fan mode relay connec-
tor.
Connector & terminal
Turbo AT model
(F17) No. 2 — (F27) No. 9:
Except turbo AT model
(F17) No. 1 — (F27) No. 9:Is the resistance less than 1
Ω?Go to step 12.Repair the open
harness between
main fan motor
connector and fan
mode relay con-
nector.
12 CHECK POOR CONTACT.
Check poor contact in main fan motor connec-
tor.Is there poor contact in main
fan motor connector?Repair poor con-
tact in main fan
motor connector.Go to step 13.
13 CHECK MAIN FAN MOTOR.
Connect the battery positive (+) terminal to ter-
minal No. 2 (except turbo AT model), No. 1
(turbo AT model), and ground (−) terminal to
terminal No. 1 (except turbo AT model), No. 2
(turbo AT model) of main fan motor.Does the main fan rotate? Go to step 14.Replace the main
fan motor with new
one. Step Check Yes No

CO(H4SO)-16
COOLING
Radiator Fan System
14 CHECK FAN MODE RELAY.
Measure the resistance of fan mode relay.
Te r m i n a l
No. 6 — No. 9:Is the resistance less than 1
Ω?Go to step 15.Replace the fan
mode relay.
15 CHECK RESISTANCE BETWEEN FAN
MODE RELAY TERMINAL AND SUB FAN
MOTOR CONNECTOR.
1) Disconnect the connector from sub fan
motor.
2) Measure the resistance between fan mode
relay terminal and sub fan motor connector.
Connector & terminal
Turbo AT model
(F16) No. 1 — (F27) No. 6:
Except turbo AT model
(F16) No. 2 — (F27) No. 6:Is the resistance less than 1
Ω?Go to step 16.Repair the open
harness between
fan mode relay ter-
minal and sub fan
motor connector.
16 CHECK SUB FAN MOTOR AND GROUND
CIRCUIT.
Measure the resistance between sub fan motor
connector and chassis ground.
Connector & terminal
Turbo AT model
(F16) No. 2 — Chassis ground:
Except turbo AT model
(F16) No. 1 — Chassis ground:Is the resistance less than 5
Ω?Go to step 17.Repair the open
harness between
sub fan motor con-
nector and chassis
ground.
17 CHECK POOR CONTACT.
Check poor contact in sub fan motor connec-
tor.Is there poor contact in sub fan
motor connector?Repair poor con-
tact in sub fan
motor connector.Go to step 18.
18 CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to ter-
minal No. 2 (except turbo AT model), No. 1
(turbo AT model), and ground (−) terminal to
terminal No. 1 (except turbo AT model), No. 2
(turbo AT model) of sub fan motor.Does the sub fan rotate? Go to step 19.Replace the sub
fan motor with new
one.
19 CHECK HARNESS BETWEEN MAIN FAN
RELAY AND ECM.
1) Disconnect the connector from ECM.
2) Measure the resistance between fan relay 1
terminal and ECM connector.
Connector & terminal
Turbo model
(B135) No. 25 — (F27) No. 32:
Non-turbo model
(B134) No. 14 — (F27) No. 32:Is the resistance less than 1
Ω?Go to step 20.Repair the open
harness between
fan relay 1 terminal
and ECM.
20 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair poor con-
tact in ECM con-
nector.Contact with SUB-
ARU dealers.
21 CHECK POWER SUPPLY TO SUB FAN RE-
LAY.
1) Turn the ignition switch to OFF.
2) Remove the sub fan relay from A/C relay
holder.
3) Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 28 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 22.Go to step 23. Step Check Yes No

CO(H4SO)-17
COOLING
Radiator Fan System
22 CHECK POWER SUPPLY TO SUB FAN RE-
LAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 25 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 26.Go to step 25.
23 CHECK FUSE.
1) Remove the fuse from A/C relay holder.
2) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Go to step 24.
24 CHECK HARNESS BETWEEN FUSE TERMI-
NAL AND SUB FAN RELAY TERMINAL.
1) Turn the ignition switch to OFF.
2) Measure the resistance between fuse ter-
minal and sub fan relay terminal.
Te r m i n a l
No. 4 — No. 28:Is the resistance less than 1
Ω?Repair the power
supply line.Repair the open
harness.
25 CHECK FUSE.
1) Turn the ignition switch to OFF.
2) Remove the fuse No. 17.
3) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Repair the power
supply line.
26 CHECK SUB FAN RELAY.
1) Turn the ignition switch to OFF.
2) Remove the sub fan relay from A/C relay
holder.
3) Measure the resistance of sub fan relay.
Te r m i n a l
No. 28 — No. 29:Is the resistance more than 1
MΩ?Go to step 27.Replace the sub
fan relay.
27 CHECK SUB FAN RELAY.
1) Connect the battery to terminals No. 25 and
No. 27 of sub fan relay.
2) Measure the resistance of sub fan relay.
Te r m i n a l
No. 28 — No. 29:Is the resistance less than 1
Ω?Go to step 28.Replace the sub
fan relay.
28 CHECK HARNESS BETWEEN SUB FAN RE-
LAY TERMINAL AND SUB FAN MOTOR
CONNECTOR.
1) Disconnect the connector from sub fan
motor.
2) Measure the resistance between sub fan
relay terminal and sub fan motor connector.
Connector & terminal
Turbo AT model
(F16) No. 1 — (F27) No. 29:
Except turbo AT model
(F16) No. 2 — (F27) No. 29:Is the resistance less than 1
Ω?Go to step 30.Repair the open
harness between
sub fan relay ter-
minal and sub fan
motor connector.
29 CHECK HARNESS BETWEEN SUB FAN RE-
LAY AND ECM.
1) Disconnect the connector from ECM.
2) Measure the resistance between sub fan
relay terminal and ECM connector.
Connector & terminal
Non-turbo model: (B134) No. 13 — (F27)
No. 27:
Turbo model: (B135) No. 24 — (F27) No.
27:Is the resistance less than 1
Ω?Go to step 30.Repair the open
harness between
sub fan relay ter-
minal and ECM. Step Check Yes No

CO(H4SO)-18
COOLING
Radiator Fan System
30 CHECK HARNESS BETWEEN FAN MODE
RELAY AND ECM.
Measure the resistance between fan mode
relay terminal and ECM connector.
Connector & terminal
Non-turbo model
(B134) No. 13 — (F27) No. 7:
Turbo model
(B135) No. 24 — (F27) No. 7:Is the resistance less than 1
Ω?Go to step 31.Repair the open
harness between
fan mode relay ter-
minal and ECM.
31 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair the poor
contact in ECM
connector.Contact with SUB-
ARU dealers.
N
OTE:
Probable cause is
deterioration of
multiple parts.
32 CHECK OPERATION OF RADIATOR FAN.Does the radiator main fan
rotate when the radiator main
and sub fan do not rotate at
high speed?Go to step 21.Go to step 33.
33 CHECK GROUND CIRCUIT OF FAN MODE
RELAY.
1) Remove the fan mode relay from A/C relay
holder.
2) Measure the resistance between fan mode
relay terminal and chassis ground.
Connector & terminal
(F27) No. 8 — Chassis ground:Is the resistance less than 1
Ω?Go to step 34.Repair the open
harness between
fan mode relay
and chassis
ground.
34 CHECK POWER SUPPLY TO FAN MODE
RELAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between fan mode
relay terminal and chassis ground.
Connector & terminal
(F27) No. 5 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 35.Repair the power
supply line.
35 CHECK FAN MODE RELAY.
1) Turn the ignition switch to OFF.
2) Remove the fan mode relay.
3) Measure the resistance of fan mode relay.
Te r m i n a l
(F27) No. 8 — (F27) No. 9:Is the resistance more than 1
MΩ?Go to step 36.Replace the fan
mode relay.
36 CHECK FAN MODE RELAY.
1) Connect the battery to terminals No. 5 and
No. 7 of fan mode relay.
2) Measure the resistance of fan mode relay.
Te r m i n a l
(F27) No. 8 — (F27) No. 9:Is the resistance less than 1
Ω?Go to step 29.Replace the fan
mode relay. Step Check Yes No

CO(H4SO)-43
COOLING
Engine Cooling System Trouble in General
12.Engine Cooling System Trouble in General
A: INSPECTION
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish the engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace the timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair the ignition control system.

nostics Procedure.>
h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace the engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair the fuel injection system.

nostics Procedure.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Defective thermostat Replace.
p. Malfunction of radiator fanInspect the radiator fan relay, engine coolant tempera-
ture sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover the radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten the cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective water pump bearing Replace the water pump.
d. Defective water pump mechanical seal Replace the water pump.

EN(H4SO)-6
ENGINE (DIAGNOSTIC)
General Description
3. General Description
A: CAUTION
1) Airbag system wiring harness is routed near the
ECM, main relay and fuel pump relay.
CAUTION:
 All air bag system wiring harnesses and con-
nectors are yellow. Do not use the electrical
test equipment on these circuits.
 Be careful not to damage the Airbag system
wiring harness when servicing the ECM, TCM,
main relay and fuel pump relay.
2) Never connect the battery in reverse polarity.
 The ECM will be destroyed immediately.
 The fuel injector and other part will be damaged.
3) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotive force will be generat-
ed in the generator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn the ignition
switch to OFF.
5) Poor contact has been identified as a primary
cause of this problem. Measure the voltage or re-
sistance of individual sensor or all electrical control
modules using a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the pin more
than 5 mm (0.20 in) into the part.
6) Remove the ECM from the located position after
disconnecting two cables on battery.
Otherwise, the ECM may be damaged.
CAUTION:
When replacing the ECM, be careful not to use
the wrong spec. ECM to avoid any damage on
the fuel injection system.
7) Connectors to each sensor in the engine com-
partment and the harness connectors on the en-
gine side and body side are all designed to be
waterproof. However, it is still necessary to take
care not to allow water to get into the connectors
when washing the vehicle, or when servicing the
vehicle on a rainy day.8) Use ECM mounting stud bolts as the grounding
point to body when measuring voltage and resis-
tance inside the passenger compartment.
9) Use engine ground terminal or engine proper as
the grounding point to body when measuring volt-
age and resistance in the engine compartment.
10) Use TCM mounting stud bolts as the grounding
point to body when measuring voltage and resis-
tance inside the passenger compartment.
11) Every MFI-related part is a precision part. Do
not drop them.
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.)
(A) Stud bolt
(A) Stud bolt
EN-00001
(A)
EN-00153
EN-00154(A)

EN(H4SO)-16
ENGINE (DIAGNOSTIC)
Electrical Component Location
 LHD MODEL
 RHD MODEL
(1) Inhibitor switch (4) Fuel pump relay (7) Starter
(2) Fuel pump (5) Radiator main fan relay
(3) Main relay (6) Radiator sub fan relay
EN-00251
(3)
(4)
EN-02400
EN-00252 (1)
(3) (7) (6)(5)(4)
(2)
EN-00253
(7) (6)(5)
(2)(3)(4)(1)