Subaru 2004 LEGACY Manuel utilisateur

FUJI HEAVY INDUSTRIES LTD. G2320GE4

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 3

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 SYSTEMS) FU(H6DO)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICES) EC(H6DO)

INTAKE (INDUCTION) IN(H6DO)

MECHANICAL ME(H6DO)

EXHAUST EX(H6DO)

COOLING CO(H6DO)

LUBRICATION LU(H6DO)

SPEED CONTROL SYSTEMS SP(H6DO)

IGNITION IG(H6DO)

STARTING/CHARGING SYSTEMS SC(H6DO)

ENGINE (DIAGNOSTICS) EN(H6DO)(diag)

ENGINE (DIAGNOSTICS)

EN(H6DO)(diag)

Page

1. Basic Diagnostic Procedure........................................................................2

2. Check List for Interview...............................................................................3

3. General Description ....................................................................................5

4. Electrical Component Location ...................................................................8

5. Engine Control Module (ECM) I/O Signal .................................................17

6. Engine Condition Data..............................................................................21

7. Data Link Connector .................................................................................22

8. OBD-II General Scan Tool........................................................................23

9. Subaru Select Monitor...............................................................................25

10. Read Diagnostic Trouble Code (DTC)......................................................32

11. Inspection Mode........................................................................................33

12. Drive Cycle................................................................................................38

13. Clear Memory Mode..................................................................................40

14. Compulsory Valve Operation Check Mode...............................................41

15. Malfunction Indicator Light........................................................................43

16. Diagnostics for Engine Starting Failure.....................................................52

17. List of Diagnostic Trouble Code (DTC).....................................................66

18. Diagnostic Procedure with Diagnostic Trouble Code (DTC).....................72

19. General Diagnostic Table........................................................................265

EN(H6DO)(diag)-72

ENGINE (DIAGNOSTICS)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

18.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

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

TEM PERFORMANCE (BANK 1)

DTC DETECTING CONDITION:

Two consecutive driving cycles with fault

TROUBLE SYMPTOM:

• Engine stalls.

• Erroneous idling

CAUTION:

After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H6DO)(diag)-40,

OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, Inspection

Mode.>.

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)”. <Ref. to

EN(H6DO)(diag)-

66, List of Diag-

nostic Trouble

Code (DTC).>

Go to step 2.

2 CHECK CURRENT DATA.

1) Start the engine and let it idle.

2) Measure the AVCS system operating angle

and oil flow control solenoid valve duty output

using Subaru Select Monitoror OBD-II general

scan tool.

NOTE:

• Subaru Select Monitor

For detailed operation procedures, refer to the

“READ CURRENT DATA SHOWN ON DIS-

PLAY FOR ENGINE”. <Ref. to

EN(H6DO)(diag)-25, 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 deg., and oil

flow control solenoid valve duty

output approx. 10%?

Check the follow-

ing and repair or

replace if neces-

sary.

• Oil pipe (clog)

• Oil flow con-

trol solenoid

valve (clog or

dirt of oil rout-

ing, setting of

spring, clog of

valve)

• Intake cam-

shaft (dirt, dam-

age of

camshaft)

• Timing chain

(matching of

timing mark)

A temporary mal-

function.

Perform the follow-

ing, and clean the

oil routing.

Replace the

engine oil and idle

the engine for 5

minutes, and then

replacetheoilfilter

and engine oil.

EN(H6DO)(diag)-73

ENGINE (DIAGNOSTICS)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

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

TEM PERFORMANCE (BANK 2)

DTC DETECTING CONDITION:

Two consecutive driving cycles with fault

TROUBLE SYMPTOM:

• Engine stalls.

• Erroneous idling

CAUTION:

After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H6DO)(diag)-40,

OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, Inspection

Mode.>.

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)”. <Ref. to

EN(H6DO)(diag)-

66, List of Diag-

nostic Trouble

Code (DTC).>

Go to step 2.

2 CHECK CURRENT DATA.

1) Start the engine and let it idle.

2) Measure the AVCS system operating angle

and oil flow control solenoid valve duty output

using Subaru Select Monitoror OBD-II general

scan tool.

NOTE:

• Subaru Select Monitor

For detailed operation procedures, refer to the

“READ CURRENT DATA SHOWN ON DIS-

PLAY FOR ENGINE”. <Ref. to

EN(H6DO)(diag)-25, 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 deg., and oil

flow control solenoid valve duty

output approx. 10%?

Check the follow-

ing and repair or

replace if neces-

sary.

• Engine oil

(amount, dirt)

• Oil pipe (clog)

• Oil flow con-

trol solenoid

valve (clog or

dirt of oil rout-

ing, setting of

spring, clog of

valve)

• Intake cam-

shaft (dirt, dam-

age of

camshaft)

• Timing chain

(matching of

timing mark)

A temporary mal-

function.

Perform the follow-

ing, and clean the

oil routing.

Replace the

engine oil and idle

the engine for 5

minutes, and then

replacetheoilfilter

and engine oil.

EN(H6DO)(diag)-74

ENGINE (DIAGNOSTICS)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (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(H6DO)(diag)-40,

OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, PROCEDURE,

Inspection Mode.>.

WIRING DIAGRAM:

BATTERY

SBF-6

B47

MAIN RELAY

B21

ECM

A34

A27

A26

A33

FRONT

OXYGEN

(A/F)

SENSOR LH

E24

B135B:B134A:

FRONT

OXYGEN

(A/F)

SENSOR RH

E47

B22

B47

5 6

A25

B22

1234

5678

10 11 12

13 14 15 16

E47 E24 B135

567

2422 23 25

11 12 13 14 15

26 27

16 17 18 19

20 21

29 30 31 32 33 34 35

B:B134

56 7

2422 23 25

11 12 13 14 15

26 27

16 17

18 19 20 21

33 3429 3230 31

A: B21

1234

12 13 14 15

5678

16 17 18 19

10 11

20 21 22

23 24 25 26 27 28 29 30 31 32 33

3534 3736 3938 4140

4342 44 45 4746

4948 5150 5352 54

EN-02495

B135B:B134A:

EN(H6DO)(diag)-75

ENGINE (DIAGNOSTICS)

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 connectors 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 — (E47) No. 1:

(B134) No. 3 — (E47) No. 1:

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. 26 — (E47) No. 4:

(B134) No. 33 — (E47) 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 MAIN RELAY

AND FRONT OXYGEN (A/F) SENSOR CON-

NECTOR.

Measure the resistance of harness between

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

nector.

Connector & terminal

(B47) No. 3 — (E47) No. 2:

Is the resistance less than 1

Ω?Go to step 4. Repair the open

circuit in harness

between main

relay and front

oxygen (A/F) sen-

sor 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(H6DO)-30,

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 inECM or

front oxygen (A/F) sensor con-

nector?

Repair the poor

contact in ECM or

front oxygen (A/F)

sensor connector.

Replace the front

oxygen (A/F) sen-

sor. <Ref. to

FU(H6DO)-30,

Front Oxygen (A/

F) Sensor.>

EN(H6DO)(diag)-76

ENGINE (DIAGNOSTICS)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

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

DTC DETECTING CONDITION:

Immediately at fault recognition

CAUTION:

After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H6DO)(diag)-40,

OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, PROCEDURE,

Inspection Mode.>.

WIRING DIAGRAM:

BATTERY

SBF-6

B47

MAIN RELAY

B21

ECM

A34

A27

A26

A33

FRONT

OXYGEN

(A/F)

SENSOR LH

E24

B135B:B134A:

FRONT

OXYGEN

(A/F)

SENSOR RH

E47

B22

B47

5 6

A25

B22

1234

5678

10 11 12

13 14 15 16

E47 E24 B135

567

2422 23 25

11 12 13 14 15

26 27

16 17 18 19

20 21

29 30 31 32 33 34 35

B:B134

56 7

2422 23 25

11 12 13 14 15

26 27

16 17

18 19 20 21

33 3429 3230 31

A: B21

1234

12 13 14 15

5678

16 17 18 19

10 11

20 21 22

23 24 25 26 27 28 29 30 31 32 33

3534 3736 3938 4140

4342 44 45 4746

4948 5150 5352 54

EN-02495

B135B:B134A:

EN(H6DO)(diag)-77

ENGINE (DIAGNOSTICS)

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

(E47) No. 2 (+) — Engine ground (

−

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

supply line.

NOTE:

In this case repair

the following:

• Open circuit in

harness between

main relay and

front oxygen (A/F)

sensor connector

• Poor contact in

front oxygen (A/F)

sensor connector

• 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. 4 — Chassis ground:

(B134) No. 5 — Chassis ground:

(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.

NOTE:

In this case repair

the following:

• Open circuit in

harness between

ECM and engine

ground terminal

• 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

the OBD-II general scan tool.

NOTE:

• Subaru Select Monitor

For detailed operation procedures, refer to the

“READ CURRENT DATA SHOWN ON DIS-

PLAY FOR ENGINE”. <Ref. to

EN(H6DO)(diag)-25, 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 the poor

contact in connec-

tor.

NOTE:

In this case repair

the following:

• Poor contact in

front oxygen (A/F)

sensor connector

• Poor contact in

coupling 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 (

−

(B134) No. 3 (+) — 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 (

−

(B134) No. 3 (+) — Chassis ground (

−

Does the voltage change by

shaking the ECM harness and

connector while monitoring the

value of voltage meter?

Repair the poor

contact in ECM

connector.

Go to step 6.

EN(H6DO)(diag)-78

ENGINE (DIAGNOSTICS)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

6 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.

NOTE:

In this case repair

the following:

• Open or ground

short circuit in har-

nessbetweenfront

oxygen (A/F) sen-

sor and ECM con-

nector

• Poor contact in

front oxygen (A/F)

sensor connector

• Poor contact in

ECM connector

• Poor contact in

coupling connector

Replace the front

oxygen (A/F) sen-

sor. <Ref. to

FU(H6DO)-30,

Front Oxygen (A/

F) Sensor.>

Step Check Yes No

EN(H6DO)(diag)-79

ENGINE (DIAGNOSTICS)

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

DTC DETECTING CONDITION:

Immediately at fault recognition

CAUTION:

After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H6DO)(diag)-40,

OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, PROCEDURE,

Inspection Mode.>.

WIRING DIAGRAM:

BATTERY

SBF-6

B47

MAIN RELAY

B21

ECM

A34

A27

A26

A33

FRONT

OXYGEN

(A/F)

SENSOR LH

E24

B135B:B134A:

FRONT

OXYGEN

(A/F)

SENSOR RH

E47

B22

B47

5 6

A25

B22

1234

5678

10 11 12

13 14 15 16

E47 E24 B135

567

2422 23 25

11 12 13 14 15

26 27

16 17 18 19

20 21

29 30 31 32 33 34 35

B:B134

56 7

2422 23 25

11 12 13 14 15

26 27

16 17

18 19 20 21

33 3429 3230 31

A: B21

1234

12 13 14 15

5678

16 17 18 19

10 11

20 21 22

23 24 25 26 27 28 29 30 31 32 33

3534 3736 3938 4140

4342 44 45 4746

4948 5150 5352 54

EN-02495

B135B:B134A:

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