Subaru 2004 Forester Manuel utilisateur

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)

ENGINE (DIAGNOSTIC)

EN(H4DOTC)

Page

1. Basic Diagnostics Procedure ......................................................................2

2. Check List for Interview...............................................................................4

3. General Description ....................................................................................6

4. Electrical Component Location ...................................................................9

5. Engine Control Module (ECM) I/O Signal .................................................23

6. Engine Condition Data ..............................................................................27

7. Transmission Control Module (TCM) I/O Signal .......................................28

8. Data Link Connector .................................................................................29

9. OBD-II General Scan Tool ........................................................................30

10. Subaru Select Monitor...............................................................................33

11. Read Diagnostic Trouble Code (DTC) ......................................................39

12. Inspection Mode........................................................................................40

13. Drive Cycle................................................................................................45

14. Clear Memory Mode..................................................................................47

15. Compulsory Valve Operation Check Mode ...............................................48

16. Malfunction Indicator Light ........................................................................50

17. Diagnostics for Engine Starting Failure.....................................................59

18. List of Diagnostic Trouble Code (DTC) .....................................................74

19. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................80

20. General Diagnostic Table........................................................................295

EN(H4DOTC)-80

ENGINE (DIAGNOSTIC)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

19.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0011 “A” CAMSHAFT POSITION - TIMING OVER - ADVANCED OR

SYSTEM PERFORMANCE (BANK 1)

DTC DETECTING CONDITION:

Detect as soon as the malfunction occurs.

TROUBLE SYMPTOM:

• Engine stalls.

• Erroneous idling

CAUTION:

After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4DOTC)-47, OP-

ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4DOTC)-40, Inspection Mode.>.

Step Check Yes No

1 CHECK DTC ON DISPLAY. Is any other DTC displayed? Inspect the rele-

vant DTC using

“List of Diagnostic

Trouble Code

(DTC)”. <Ref. to

EN(H4DOTC)-74,

List of Diagnostic

Trouble Code

(DTC).>

Go to step 2.

2 CHECK CURRENT DATA.

1) Start the engine and idle it.

2) Check the AVCS system operating angle

and oil flow control solenoid valve duty output

using Subaru Select Monitor or OBD-II general

scan tool.

TE:

• Subaru Select Monitor

For detailed operation procedure, refer to

“READ CURRENT DATA SHOWN ON DIS-

PLAY FOR ENGINE”. <Ref. to EN(H4DOTC)-

33, Subaru Select Monitor.>

• OBD-II general scan tool

For detailed operation procedures, refer to the

OBD-II General Scan Tool Operation Manual.

Is the AVCS system operating

angle approx. 0 degree and oil

flow control solenoid valve duty

output approx. 10%?

A temporary poor

malfunction. Per-

form the following

to clean oil routing.

Replace the

engine oil, and

then idle the

engine for 5 min-

utes and replace

the oil filter and

engine oil.

Check the follow-

ing and repair or

replace it if neces-

sary.

• Oil pipe (clog-

ging)

• Oil flow con-

trol solenoid

valve (clogging

or dirt of oil

routing, spring

setting, clog-

ging of valve)

• Intake cam-

shaft (dirt, dam-

age of

camshaft)

• Timing belt

(alignment of

timing mark)

EN(H4DOTC)-81

ENGINE (DIAGNOSTIC)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

B: DTC P0021 “A” CAMSHAFT POSITION - TIMING OVER - ADVANCED OR

SYSTEM PERFORMANCE (BANK 2)

DTC DETECTING CONDITION:

Detect as soon as the malfunction occurs.

TROUBLE SYMPTOM:

• Engine stalls.

• Erroneous idling

CAUTION:

After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4DOTC)-47, OP-

ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4DOTC)-40, Inspection Mode.>.

Step Check Yes No

1 CHECK DTC ON DISPLAY. Is any other DTC displayed? Inspect the rele-

vant DTC using

“List of Diagnostic

Trouble Code

(DTC)”. <Ref. to

EN(H4DOTC)-74,

List of Diagnostic

Trouble Code

(DTC).>

Go to step 2.

2 CHECK CURRENT DATA.

1) Start the engine and idle it.

2) Check the AVCS system operating angle

and oil flow control solenoid valve duty output

using Subaru Select Monitor or OBD-II general

scan tool.

NOTE:

• Subaru Select Monitor

For detailed operation procedure, refer to

“READ CURRENT DATA SHOWN ON DIS-

PLAY FOR ENGINE”. <Ref. to EN(H4DOTC)-

33, Subaru Select Monitor.>

• OBD-II general scan tool

For detailed operation procedures, refer to the

OBD-II General Scan Tool Operation Manual.

Is the AVCS system operating

angle approx. 0 degree and oil

flow control solenoid valve duty

output approx. 10%?

A temporary poor

malfunction. Per-

form the following

to clean oil routing.

Replace the

engine oil, and

then idle the

engine for 5 min-

utes and replace

the oil filter and

engine oil.

Check the follow-

ing and repair or

replace it if neces-

sary.

• Engine oil

(amount, dirt)

• Oil pipe (clog-

ging)

• Oil flow con-

trol solenoid

valve (clogging

or dirt of oil

routing, spring

setting, clog-

ging of valve)

• Intake cam-

shaft (dirt, dam-

age of

camshaft)

• Timing belt

(alignment of

timing mark)

EN(H4DOTC)-82

ENGINE (DIAGNOSTIC)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

C: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

DTC DETECTING CONDITION:

Two consecutive driving cycles with fault

CAUTION:

After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4DOTC)-47, OP-

ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4DOTC)-40, Inspection Mode.>.

WIRING DIAGRAM:

EN-02320

BATTERY

MAIN RELAY

SBF-5

B47

B100 F2

14 LHD

RHD

LHD

RHD

B100

F60

203

RHD

ECM

B134

: LHD

B21 : RHD

: RHD

B262

FRONT OXYGEN

(A/F) SENSOR

1234

5678

10 11 12

13 14 15 16

B21

F60

B47

B262

B134

LHDLHD

56 7

2422 23 25

11 12 13 14 15

26 27

16 17

18 19 20 21

33 3429 3230 31

1234 56789

10 11 12 13 14 15 16 17 18 19 20

: LHD E2 : RHD

EN(H4DOTC)-83

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) Start the engine, and warm-up the engine.

2) Turn the ignition switch to OFF.

3) Disconnect the connector from ECM and

front oxygen (A/F) sensor.

4) Measure the resistance of harness

between ECM and front oxygen (A/F) sensor

connector.

Connector & terminal

(B134)No. 2 — (B262)No. 2:

(B134)No. 3 — (B262)No. 2:

Is the resistance less than 1

Ω?

Go to step 2. Repair the open

circuit in harness

between ECM and

front oxygen (A/F)

sensor connector.

2 CHECK HARNESS BETWEEN ECM AND

FRONT OXYGEN (A/F) SENSOR CONNEC-

TOR.

Measure the resistance of harness between

ECM and front oxygen (A/F) sensor connector.

Connector & terminal

(B134) No. 33 — (B262) No. 4:

(B134) No. 26 — (B262) No. 3:

Is the resistance less than 1

Ω?

Go to step 3. Repair the open

circuit in harness

between ECM and

front oxygen (A/F)

sensor connector.

3 CHECK HARNESS BETWEEN ECM AND

FRONT OXYGEN (A/F) SENSOR CONNEC-

TOR.

Measure the resistance of harness between

main relay and front oxygen (A/F) sensor con-

nector.

Connector & terminal

(B47) No. 4 — (B262) No. 1:

Is the resistance less than 1

Ω?

Go to step 4. Repair the open

circuit in harness

between ECM and

front oxygen (A/F)

sensor connector.

4 CHECK FRONT OXYGEN (A/F) SENSOR.

Measure the resistance between front oxygen

(A/F) sensor connector terminals.

Terminals

No. 2 — No. 1:

Is the resistance less than 5

Ω?

Go to step 5. Replace the front

oxygen (A/F) sen-

sor. <Ref. to

FU(H4DOTC)-45,

Front Oxygen (A/

F) Sensor.>

5 CHECK POOR CONTACT.

Check poor contact in ECM and front oxygen

(A/F) sensor connector.

Is there poor contact in ECM or

front oxygen (A/F) sensor con-

nector?

Repair the poor

contact in ECM

and front oxygen

(A/F) sensor.

Replace the front

oxygen (A/F) sen-

sor. <Ref. to

FU(H4DOTC)-45,

Front Oxygen (A/

F) Sensor.>

EN(H4DOTC)-84

ENGINE (DIAGNOSTIC)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

DTC DETECTING CONDITION:

Detect as soon as the malfunction occurs.

CAUTION:

After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4DOTC)-47, OP-

ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4DOTC)-40, Inspection Mode.>.

WIRING DIAGRAM:

EN-02320

BATTERY

MAIN RELAY

SBF-5

B47

B100 F2

14 LHD

RHD

LHD

RHD

B100

F60

203

RHD

ECM

B134

: LHD

B21 : RHD

: RHD

B262

FRONT OXYGEN

(A/F) SENSOR

1234

5678

10 11 12

13 14 15 16

B21

F60

B47

B262

B134

LHDLHD

56 7

2422 23 25

11 12 13 14 15

26 27

16 17

18 19 20 21

33 3429 3230 31

1234 56789

10 11 12 13 14 15 16 17 18 19 20

: LHD E2 : RHD

EN(H4DOTC)-85

ENGINE (DIAGNOSTIC)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

1 CHECK POWER SUPPLY TO FRONT OXY-

GEN (A/F) SENSOR.

1) Turn the ignition switch to OFF.

2) Disconnect the connector from front oxygen

(A/F) sensor.

3) Turn the ignition switch to ON.

4) Measure the voltage between front oxygen

(A/F) sensor connector and engine ground.

Connector & terminal

(B262) No. 1 (+) — Engine ground (

−

Is the voltage more than 10 V? Go to step 2. Repair the power

supply line.

TE:

In this case repair

the following:

• Open circuit in

harness between

main relay and

front oxygen (A/F)

sensor

• CHECK POOR

CONTACT OF

FRONT OXYGEN

(A/F) SENSOR.

• Poor contact in

main relay connec-

tor

2 CHECK GROUND CIRCUIT FOR ECM.

Measure the resistance of harness between

ECM connector and chassis ground.

Connector & terminal

(B134) No. 6 — Chassis ground:

(B134) No. 7 — Chassis ground:

Is the resistance less than 5

Ω?

Go to step 3. Repair the har-

ness and connec-

tor.

TE:

In this case repair

the following:

• Open circuit in

harness between

ECM and engine

ground cable

• Poor contact in

ECM connector.

• Poor contact in

coupling connector

3 CHECK CURRENT DATA.

1) Start the engine.

2) Read the data of front oxygen (A/F) sensor

heater current using Subaru Select Monitor or

OBD-II general scan tool.

TE:

• Subaru Select Monitor

For detailed operation procedure, refer to

“READ CURRENT DATA SHOWN ON DIS-

PLAY FOR ENGINE”. <Ref. to EN(H4DOTC)-

33, Subaru Select Monitor.>

• OBD-II general scan tool

For detailed operation procedures, refer to the

OBD-II General Scan Tool Operation Manual.

Is the current more than 0.2 A? Repair poor con-

tact connector.

TE:

In this case repair

the following:

• Poor contact in

front oxygen (A/F)

sensor connector

• Poor contact in

ECM connector.

Go to step 4.

4 CHECK OUTPUT SIGNAL FROM ECM.

1) Start and idle the engine.

2) Measure the voltage between ECM con-

nector and chassis ground.

Connector & terminal

(B134) No. 2 (+) — Chassis ground (

−

Is the voltage less than 1 V? Go to step 6. Go to step 5.

5 CHECK OUTPUT SIGNAL FROM ECM.

Measure the voltage between ECM connector

and chassis ground.

Connector & terminal

(B134) No. 2 (+) — Chassis ground (

−

Does the voltage change by

shaking the harness and con-

nector of ECM while monitor-

ing the value with voltage

meter?

Repair the poor

contact in ECM

connector.

Go to step 6.

EN(H4DOTC)-86

ENGINE (DIAGNOSTIC)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

6 CHECK OUTPUT SIGNAL FROM ECM.

Measure the voltage between ECM connector

and chassis ground.

Connector & terminal

(B134) No. 3 (+) — Chassis ground (

−

Is the voltage less than 1 V? Go to step 8. Go to step 7.

7 CHECK OUTPUT SIGNAL FROM ECM.

Measure the voltage between ECM connector

and chassis ground.

Connector & terminal

(B134) No. 3 (+) — Chassis ground (

−

Does the voltage change by

shaking the harness and con-

nector of ECM while monitor-

ing the value with voltage

meter?

Repair the poor

contact in ECM

connector.

Go to step 8.

8 CHECK FRONT OXYGEN (A/F) SENSOR.

1) Turn the ignition switch to OFF.

2) Measure the resistance between front oxy-

gen (A/F) sensor connector terminals.

Terminals

No. 2 — No. 1:

Is the resistance less than 10

Ω?

Repair the har-

ness and connec-

tor.

TE:

In this case repair

the following:

• Open or ground

short circuit in har-

ness between front

oxygen (A/F) sen-

sor and ECM con-

nector

• Poor contact in

front oxygen (A/F)

sensor connector

• Poor contact in

ECM connector.

Replace the front

oxygen (A/F) sen-

sor. <Ref. to

FU(H4DOTC)-45,

Front Oxygen (A/

F) Sensor.>

Step Check Yes No

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