engine SUBARU FORESTER 2004 Service Repair Manual

EN(H4DOTC)-165
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
RHD model
EN-02319
BATTERY
FUEL INJECTORS MAIN RELAY
E#4
1 2
SBF-5
#3
1
2
#2
1 2
#1
1
2
1
9
10
11
12
12
12
7
8956 3410 11 12
19 20 2113 14 1516
17 1822
23
24123
4
56
78
9
1011 12
1314 15 16
6
4
5
3
2
1
B21
B21B136E5
E5
F2
E6
E6
E16
E16
E17
B47
E17
6
5
4
3
B136ECM
B47
34
12
56

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)”. EN(H4DOTC)-74,
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. to FU(H4DOTC)-
38, Fuel Injector.>

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. FU(H4DOTC)-50,
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. FU(H4DOTC)-38,
Fuel Injector.>
FU(H4DOTC)-50,
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. ME(H4DOTC)-67,
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. ME(H4DOTC)-58,
Timing Belt
Assembly.>Go to step 12. Step Check Yes No

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.
Mode.>
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. to EN(H4DOTC)-
148, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).> Step Check Yes No

EN(H4DOTC)-169
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AO:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE
SENSOR)
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
 Poor driving performance
 Knocking occurs.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode ERATION, Clear Memory Mode.> and Inspection Mode .
WIRING DIAGRAM:
EN-02329
E1
E14
B20
KNOCK
SENSOR
2
6
B136 ECM
3325
E
E14
12
12 34
56
7
89
10
B20
B136
56
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35

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. FU(H4DOTC)-33,
Knock Sensor.>Tighten knock sen-
sor installation bolt
securely.

EN(H4DOTC)-171
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AP:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SINGLE
SENSOR)
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
 Poor driving performance
 Knocking occurs.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode ERATION, Clear Memory Mode.> and Inspection Mode .
WIRING DIAGRAM:
EN-02329
E1
E14
B20
KNOCK
SENSOR
2
6
B136 ECM
3325
E
E14
12
12 34
56
7
89
10
B20
B136
56
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35

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. FU(H4DOTC)-33,
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.

EN(H4DOTC)-173
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
AQ:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
 Engine stalls.
 Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode ERATION, Clear Memory Mode.> and Inspection Mode .
WIRING DIAGRAM:
EN-02330
2
1E1
E10
B20
CRANKSHAFT
POSITION
SENSOR
2
1
B135 ECM
22
31 10
E
E10
12
12 34
56
7
89
10
B20
B135
567
82 1
94 310
24 22 23 2511 12 13 14 15
26 27
2816 17 18 19
20 21
29 30 31 32 33 34 35

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. FU(H4DOTC)-30,
Crankshaft Posi-
tion Sensor.>