2004 SUBARU FORESTER transmission

EN(H4DOTC)-238
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
BU:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
NOTE:
For the diagnostic procedure, refer to AT section. Procedure.>
Step Check Yes No
1 CHECK OUTPUT SIGNAL FROM ECM.
1) Turn the ignition switch to OFF.
2) Connect the test mode connector.
3) Turn the ignition switch to ON.
4) While operating the radiator fan relay, mea-
sure voltage between ECM and chassis
ground.
N
OTE:
Radiator fan relay operation can be executed
using Subaru Select Monitor.For procedure, re-
fer to “Compulsory Valve Operation Check
Mode”. Valve Operation Check Mode.>
Connector & terminal
(B135) No. 24 (+) — Chassis ground (
−):
(B135) No. 25 (+) — Chassis ground (
−):Does the voltage vary between
0 — 10 V?Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time.In this
case, repair poor
contact in ECM
connector.Go to step 2.
2 CHECK SHORT CIRCUIT IN RADIATOR FAN
RELAY CONTROL CIRCUIT.
1) Turn the ignition switch to OFF.
2) Remove the main fan relay 1, sub fan relay
and fan mode relay.
3) Disconnect the test mode connectors
4) Turn the ignition switch to ON.
5) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B135) No. 24 (+) — Chassis ground (
−):
(B135) No. 25 (+) — Chassis ground (
−):Is the voltage more than 10 V? Repair battery
short circuit in
radiator fan relay
control cir-
cuit.After repair,
replace the ECM.
FU(H4DOTC)-50,
Engine Control
Module (ECM).>Go to step 3.
3 CHECK MAIN FAN RELAY 1.
1) Turn the ignition switch to OFF.
2) Remove the main fan relay1.
3) Measure the resistance of main fan relay 1
terminals.
Te r m i n a l s
No. 30 — No. 31:Is the resistance less than 1
Ω?Replace the main
fan relay 1 and
ECM. FU(H4DOTC)-50,
Engine Control
Module (ECM).>Go to step 4.
4 CHECK SUB FAN RELAY.
1) Remove the sub fan relay.
2) Measure the resistance between sub fan
relay terminals.
Te r m i n a l s
No. 28 — No. 29:Is the resistance less than 1
Ω?Replace the sub
fan relay and
ECM. FU(H4DOTC)-50,
Engine Control
Module (ECM).>Go to step 5.
5 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair the poor
contact in ECM
connector.Replace the ECM.
FU(H4DOTC)-50,
Engine Control
Module (ECM).>

EN(H4DOTC)-240
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK INPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.
2) Shift the select lever to other than “N” and
“P” ranges.
3) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B137) No. 9 (+) — Chassis ground (
−):Is the voltage 4.5 — 5.5 V? Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time.Go to step 2.
2 CHECK HARNESS BETWEEN ECM AND
TRANSMISSION HARNESS CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connectors from ECM and
transmission harness connector (T3).
3) Measure the resistance of harness
between ECM connector and chassis ground.
Connector & terminal
(B137) No. 9 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 3.Repair ground
short circuit in har-
ness between
ECM and trans-
mission harness
connector.
3 CHECK TRANSMISSION HARNESS CON-
NECTOR.
1) Disconnect the connector from inhibitor
switch.
2) Measure the resistance of harness
between transmission harness connector and
engine ground.
Connector & terminal
(T3) No. 12 — Engine ground:Is the resistance more than 1
MΩ?Go to step 4.Repair ground
short circuit in har-
ness between
transmission har-
ness and inhibitor
switch connector.
4 CHECK INHIBITOR SWITCH.
Measure the resistance between inhibitor
switch connector the receptacle’s terminals in
selector lever except for “N” range.
Te r m i n a l s
No. 7 — No. 12:Is the resistance more than 1
MΩ?Go to step 5.Replace the inhibi-
tor switch. 4AT-51, Inhibitor
Switch.>
5 CHECK SELECTOR CABLE CONNECTION.Is there any fault in selector
cable connection to inhibitor
switch?Repair selector
cable connection.
INSPECTION,
Select Cable.>Contact the SUB-
ARU dealer.
N
OTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.

EN(H4DOTC)-242
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK INPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.
2) Place the shift lever in neutral.
3) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B137) No. 9 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 2.Go to step 4.
2 CHECK INPUT SIGNAL FROM ECM.
1) Place the shift lever except in neutral.
2) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B137) No. 9 (+) — Chassis ground (
−):Is the voltage less than 1 V? Go to step 3.Go to step 4.
3 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair the poor
contact in ECM
connector.Contact the SUB-
ARU dealer.
4 CHECK NEUTRAL POSITION SWITCH.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from transmis-
sion harness.
3) Place the shift lever in neutral.
4) Measure the resistance between transmis-
sion harness and connector terminals.
Connector & terminal
(T9) No. 1 — No. 3:Is the resistance more than 1
MΩ?Go to step 5.Repair short circuit
in transmission
harness or replace
the neutral position
switch.
5 CHECK NEUTRAL POSITION SWITCH.
1) Place the shift lever except in neutral.
2) Measure the resistance between transmis-
sion harness connector terminals.
Te r m i n a l s
No. 1 — No. 3:Is the resistance less than 1
Ω?Go to step 6.Repair short circuit
in transmission
harness or replace
the neutral position
switch.
6 CHECK HARNESS BETWEEN ECM AND
NEUTRAL POSITION SWITCH CONNEC-
TOR.
Measure the resistance between ECM and
chassis ground.
Connector & terminal
(B137) No. 9 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 7.Repair ground
short circuit in har-
ness between
ECM and trans-
mission harness
connector.
7 CHECK HARNESS BETWEEN ECM AND
NEUTRAL POSITION SWITCH CONNEC-
TOR.
1) Disconnect the connector from ECM.
2) Measure the resistance of harness
between ECM and transmission harness con-
nector.
Connector & terminal
(B137) No. 9 — (B128) No. 1:Is the resistance less than 1
Ω?Go to step 8.Repair open circuit
in harness
between ECM and
transmission har-
ness connector.
8 CHECK HARNESS BETWEEN ECM AND
NEUTRAL POSITION SWITCH CONNEC-
TOR.
Measure the resistance of harness between
transmission harness connector and engine
ground.
Connector & terminal
(B128) No. 1 — Engine ground:Is the resistance less than 5
Ω?Go to step 9.Repair open circuit
between transmis-
sion harness con-
nector and engine
ground terminal.
9 CHECK POOR CONTACT.
Check poor contact in transmission harness
connector.Is there poor contact in trans-
mission harness connector?Repair poor con-
tact in transmis-
sion harness
connector.Contact the SUB-
ARU dealer.

EN(H4DOTC)-247
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK INPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON.
2) Place the shift lever except in neutral posi-
tion.
3) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B137) No. 9 (+) — Chassis ground (
−):Is the voltage less than 1 V? Go to step 2.Go to step 4.
2 CHECK INPUT SIGNAL FROM ECM.
1) Place the shift lever in neutral position.
2) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B137) No. 9 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 3.Go to step 4.
3 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair the poor
contact in ECM
connector.Contact the SUB-
ARU dealer.
4 CHECK INPUT SIGNAL FROM ECM.
1) Disconnect the connector from ECM.
2) Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B137) No. 9 (+) — Chassis ground (
−):Is the voltage more than 10 V? Repair battery
short circuit in har-
ness between
ECM and trans-
mission harness
connector.Go to step 5.
5 CHECK HARNESS BETWEEN ECM AND
TRANSMISSION HARNESS CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connectors from ECM and
transmission harness connector (T9).
3) Measure the resistance of harness
between ECM and neutral switch connector.
Connector & terminal
(B137) No. 9 — (B128) No. 1:Is the resistance less than 1
Ω?Go to step 6.Repair the har-
ness and connec-
tor.
NOTE:
In this case repair
the following:
 Open circuit in
harness between
ECM and trans-
mission harness
connector
 Poor contact in
transmission har-
ness connector.
 Poor contact in
ECM connector.
6 CHECK NEUTRAL POSITION SWITCH
GROUND LINE.
Measure the resistance of harness between
transmission harness connector and engine
ground.
Connector & terminal
(B128) No. 3 — Engine ground:Is the resistance less than 5
Ω?Go to step 7.Repair open circuit
in the neutral posi-
tion switch ground
line.
7 CHECK NEUTRAL POSITION SWITCH.
1) Place the shift lever except in neutral posi-
tion.
2) Measure the resistance between transmis-
sion harness connector socket terminals.
Te r m i n a l s
No. 1 — No. 3:Is the resistance less than 1
Ω?Go to step 8.Replace the neu-
tral position switch.
8 CHECK POOR CONTACT.
Check poor contact in transmission harness
connector.Is there poor contact in trans-
mission harness connector?Repair poor con-
tact in transmis-
sion harness
connector.Contact the SUB-
ARU dealer.

FU(H4DOTC 2.5)-46
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
22.Fuel Tank
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Set the vehicle on a lift.
2) Release the fuel pressure.
FUEL PRESSURE, OPERATION, Fuel.>
3) Drain fuel from the fuel tank.
OPERATION, Fuel.>
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to
rear harness.
6) Push the grommet (B) which holds fuel tank cord
on floor panel into under the body.
7) Remove the rear crossmember. REMOVAL, Rear Crossmember.>
8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B)
from canister.9) Loosen the clamp and disconnect the fuel filler
hose and air vent hose from fuel filler pipe.
10) Move the clips, and disconnect quick connec-
tor. Delivery, Return and Evaporation Lines.>
11) Disconnect the fuel hoses.
12) Support the fuel tank with transmission jack,
and remove the bolts from bands and dismount fuel
tank from the vehicle.
WARNING:
A helper is required to perform this work.
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
(B)
(A)
FU-00090
(A)
(B)
FU-00091
FU-00092
FU-00093
FU-00411

EN(H4DOTC 2.5)-16
ENGINE (DIAGNOSTIC)
Electrical Component Location
2. TRANSMISSION
 SOLENOID VALVE & SWITCH (MT MODEL)
(1) Neutral Position Switch
EN-00102
(6)
(7)
(5)
EN-00103
(8)
EN-00192 (1)

EN(H4DOTC 2.5)-35
ENGINE (DIAGNOSTIC)
Inspection Mode
11.Inspection Mode
A: OPERATION
Perform the diagnosis on the “Diagnosis Trouble Codes (DTC) List” below.
Refer to the item of drive cycle when perform the diagnosis not on the “Diagnosis Trouble Codes (DTC) List”
below.
DTC Item On condition
P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1) —
P0032 HO2S Heater Control Circuit High (Bank 1 Sensor 1) —
P0037 HO2S Heater Control Circuit Low (Bank 1 Sensor 2) —
P0038 HO2S Heater Control Circuit High (Bank 1 Sensor 2) —
P0102 Mass or Volume Air Flow Circuit Low Input —
P0103 Mass or Volume Air Flow Circuit High Input —
P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input —
P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input —
P0112 Intake Air Temperature Circuit Low Input —
P0113 Intake Air Temperature Circuit High Input —
P0117 Engine Coolant Temperature Circuit Low Input —
P0118 Engine Coolant Temperature Circuit High Input —
P0122 Throttle/Pedal Position Sensor/Switch “A” Circuit Low Input —
P0123 Throttle/Pedal Position Sensor/Switch “A” Circuit High Input —
P0131 O
2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
—
P0132 O
2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
—
P0137 O
2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)
—
P0138 O
2 Sensor Circuit High Voltage (Bank 1 Sensor 2)
—
P0222 Throttle/Pedal Position Sensor/Switch “B” Circuit Low Input —
P0223 Throttle/Pedal Position Sensor/Switch “B” Circuit High Input —
P0230 Fuel Pump Primary Circuit —
P0245 Turbo/Super Charger Wastegate Solenoid “A” Low —
P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) —
P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) —
P0335 Crankshaft Position Sensor “A” Circuit —
P0340 Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor) —
P0345 Camshaft Position Sensor “A” Circuit (Bank 2) —
P0458 Evaporative Emission Control System Purge Control Valve Circuit Low —
P0459 Evaporative Emission Control System Purge Control Valve Circuit High —
P0462 Fuel Level Sensor Circuit Low Input —
P0463 Fuel Level Sensor Circuit High Input —
P0502 Vehicle Speed Sensor Circuit Low Input —
P0503 Vehicle Speed Sensor Intermittent/Erratic/High —
P0512 Starter Request Circuit—
P0513 Incorrect Immobilizer Key —
P0519 Idle Control System Malfunction (Fail-Safe) —
P0545 Exhaust Gas Temperature Sensor Circuit Low-Bank 1 —
P0600 Serial Communication Link —
P0604 Internal Control Module Random Access Memory (RAM) Error —
P0605 Internal Control Module Read Only Memory (ROM) Error —
P0607 Control Module Performance —
P0638 Throttle Actuator Control Range/Performance (Bank 1) —
P0691 Cooling Fan 1 Control Circuit Low —
P0700 Transmission Control System (MIL Request) —
P0851 Neutral Switch Input Circuit Low —

EN(H4DOTC 2.5)-67
ENGINE (DIAGNOSTIC)
List of Diagnostic Trouble Code (DTC)
P0512 Starter Request Circuit Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0513 Incorrect Immobilizer Key Procedure with Diagnostic Trouble Code (DTC).>
P0519 Idle Control System Malfunction
(Fail-Safe) MALFUNCTION (FAIL-SAFE), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0545 Exhaust Gas Temperature Sensor
Circuit Low-Bank 1 TURE SENSOR CIRCUIT LOW - BANK 1, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0546 Exhaust Gas Temperature Sensor
Circuit High-Bank 1 TURE SENSOR HIGH - BANK 1, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
P0600 Serial Communication Link LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0604 Internal Control Module Random
Access Memory (RAM) Error ULE READ ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P0605 Internal Control Module Read
Access Memory (RAM) Error ULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P0607 Control Module Performance MANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0638 Throttle Actuator Control Range/
Performance (Bank 1) TROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0691 Cooling Fan 1 Control Circuit Low CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0692 Cooling Fan 1 Control Circuit High CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0700 Transmission Control System (MIL
Request) SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0851 Neutral Switch Input Circuit Low CIRCUIT LOW (MT MODEL), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0852 Neutral Switch Input Circuit High CIRCUIT HIGH (AT MODEL), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1086 Tumble Generated Valve Position
Sensor 2 Circuit Low POSITION SENSOR 2 CIRCUIT LOW, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
P1087 Tumble Generated Valve Position
Sensor 2 Circuit High POSITION SENSOR 2 CIRCUIT HIGH, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
P1088 Tumble Generated Valve Position
Sensor 1 Circuit Low POSITION SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
P1089 Tumble Generated Valve Position
Sensor 1 Circuit High POSITION SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
P1090 Tumble Generated Valve System 1
(Valve Open) SYSTEM 1 (VALVE OPEN), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1091 Tumble Generated Valve System 1
(Valve Close) SYSTEM 1 (VALVE CLOSE), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).> DTC Item NOTE