2004 SUBARU FORESTER replace disc

EN(H4SO)-54
ENGINE (DIAGNOSTIC)
Malfunction Indicator Light
Step Check Yes No
1 CHECK STATUS OF MALFUNCTION INDI-
CATOR LIGHT.
1) Turn the ignition switch to OFF.
2) Disconnect the test mode connectors
3) Turn the ignition switch to ON. (engine
OFF)Does malfunction indicator
light illuminate?Go to step 2.Repair the mal-
function indictor
light circuit. to EN(H4SO)-49,
MALFUNCTION
INDICATOR
LIGHT DOES
NOT COME ON,
Malfunction Indica-
tor Light.>
2 CHECK HARNESS BETWEEN COMBINA-
TION METER AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Turn the ignition switch to ON.Does malfunction indicator
light illuminate?Repair short circuit
in harness
between combina-
tion meter and
ECM connector.Go to step 3.
3 CHECK HARNESS BETWEEN TEST MODE
CONNECTOR AND CHASSIS GROUND.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Measure the resistance of harness
between test mode connector and chassis
ground.
Connector & terminal
(B76) No. 1 — Chassis ground:Is the resistance less than 1
Ω?Go to step 4.Repair harness
and connector.
N
OTE:
In this case repair
the following:
 Open circuit in
harness between
test mode connec-
tor and chassis
ground
4 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair the poor
contact in ECM
connector.Go to step 5.
5 CHECK HARNESS BETWEEN ECM AND
TEST MODE CONNECTOR.
1) Connect the test mode connector.
2) Measure the resistance of harness
between ECM and chassis ground.
Connector & terminal
(B136) No. 3 — Chassis ground:Is the resistance less than 1
Ω?Go to step 6.Repair open circuit
in harness
between ECM and
test mode connec-
tor.
6 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(H4SO)-44,
Engine Control
Module (ECM).>

EN(H4SO)-56
ENGINE (DIAGNOSTIC)
Malfunction Indicator Light
Step Check Yes No
1 CHECK TEST MODE CONNECTOR.
1) Disconnect the test mode connectors
2) Turn the ignition switch to ON.Does the malfunction indicator
light blink?Go to step 2.System is in good
order.
N
OTE:
Malfunction indica-
tor light blinks at a
cycle of 3 Hz when
test mode connec-
tor is connected.
2 CHECK HARNESS BETWEEN ECM CON-
NECTOR AND CHASSIS GROUNDING TER-
MINAL.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Measure the resistance of harness
between ECM connector and chassis ground.
Connector & terminal
(B136) No. 3 — Chassis ground:Is the resistance less than 5
Ω?Repair the short
circuit in harness
between ECM and
test mode connec-
tor.Replace the ECM.
FU(H4SO)-44,
Engine Control
Module (ECM).>

EN(H4SO)-59
ENGINE (DIAGNOSTIC)
Diagnostics for Engine Starting Failure
Step Check Yes No
1 CHECK BATTERY.
Check the battery voltage.Is the voltage more than 12 V? Go to step 2.Charge or replace
the battery.
2 CHECK INPUT SIGNAL FOR STARTER MO-
TOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from starter
motor.
3) Turn the ignition switch to START.
4) Measure the power supply voltage between
starter motor connector terminal and engine
ground.
Connector & terminal
(B14) No. 1 (+) — Engine ground (
−):
N
OTE:
 For AT model, shift the select lever to “P” or
“N” range.
 For MT model, depress the clutch pedal.Is the voltage more than 10 V? Go to step 3.Go to step 4.
3 CHECK GROUND CIRCUIT OF STARTER
MOTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable terminal from
starter motor.
3) Measure the resistance of ground cable
between ground cable terminal and engine
ground.Is the resistance less than 5
Ω?Check the starter
motor. SC(H4SO)-6,
Starter.>Repair open circuit
of ground cable.
4 CHECK HARNESS BETWEEN BATTERY
AND IGNITION SWITCH CONNECTOR.
1) Disconnect the connector from ignition
switch.
2) Measure the power supply voltage between
ignition switch connector and chassis ground.
Connector & terminal
(B72) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 5.Repair open circuit
in harness
between ignition
switch and bat-
tery, and check
fuse SBF No. 4
and SBF No. 1.
5 CHECK IGNITION SWITCH.
1) Disconnect the connector from ignition
switch.
2) Measure the resistance between ignition
switch terminals while turning the ignition
switch to START position.
Te r m i n a l s
No. 1 — No. 3:Is the resistance less than 5
Ω?Go to step 6.Replace the igni-
tion switch.
6 CHECK TRANSMISSION TYPE.Is the transmission type AT? Go to step 7.Temporary poor
contact occurs.
Check poor con-
tact in each con-
nectors.
7 CHECK INHIBITOR SWITCH INPUT VOLT-
AGE.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from inhibitor
switch.
3) Connect the connector to ignition switch.
4) Measure the input voltage between inhibitor
switch connector terminal and engine ground
while turning the ignition switch to START posi-
tion.
Connector & terminal
(B12) No. 12 (+) — Engine ground (
−):Is the voltage more than 10 V? Go to step 8.Repair open or
ground short cir-
cuit in harness
between inhibitor
switch and ignition
switch.
N
OTE:
Check security sys-
tem (if equipped).

EN(H4SO)-62
ENGINE (DIAGNOSTIC)
Diagnostics for Engine Starting Failure
Step Check Yes No
1 CHECK MAIN RELAY.
1) Turn the ignition switch to OFF.
2) Remove the main relay.
3) Connect the battery to main relay terminals
No. 1 and No. 2.
4) Measure the resistance between main relay
terminals.
Te r m i n a l s
No. 3 — No. 5:
No. 4 — No. 6:Is the resistance less than 10
Ω?Go to step 2.Replace the main
relay.
2 CHECK GROUND CIRCUIT FOR ECM.
1) Disconnect the connector from ECM.
2) Measure the resistance of harness
between ECM and chassis ground.
Connector & terminal
(B134) No. 7 — Chassis ground:
(B134) No. 35 — Chassis ground:
(B135) No. 21 — Chassis ground:
(B136) No. 5 — Chassis ground:
(B136) No. 16 — Chassis ground:
(B136) No. 19 — Chassis ground: (MT
model)
(B136) No. 26 — Chassis ground:
(B137) No. 14 — Chassis ground:Is the resistance less than 5
Ω?Go to step 3.Repair open circuit
in harness
between ECM
connector and
engine ground ter-
minal.
3 CHECK INPUT VOLTAGE OF ECM.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(B135) No. 9 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 4.Repair open or
ground short cir-
cuit of power sup-
ply circuit.
4 CHECK INPUT VOLTAGE OF ECM.
1) Turn the ignition switch to ON.
2) Measure the voltage between ECM con-
nector and chassis ground.
Connector & terminal
(B136) No. 10 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 5.Repair open or
ground short cir-
cuit of power sup-
ply circuit.
5 CHECK HARNESS BETWEEN ECM AND
MAIN RELAY CONNECTOR.
1) Turn the ignition switch to OFF.
2) Measure the resistance between ECM and
chassis ground.
Connector & terminal
(B136) No. 12 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 6.Repair ground
short circuit in har-
ness between
ECM connector
and main relay
connector, then
replace the ECM.
6 CHECK OUTPUT VOLTAGE FROM ECM.
1) Connect the connector to ECM.
2) Turn the ignition switch to ON.
3) Measure the voltage between ECM con-
nector and chassis ground.
Connector & terminal
(B136) No. 12 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 7.Replace the ECM.
FU(H4SO)-44,
Engine Control
Module (ECM).>
7 CHECK INPUT VOLTAGE OF MAIN RELAY.
Measure the voltage between main relay con-
nector and chassis ground.
Connector & terminal
(B47) No. 2 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 8.Repair open circuit
in harness
between ECM
connector and
main relay connec-
tor.

EN(H4SO)-65
ENGINE (DIAGNOSTIC)
Diagnostics for Engine Starting Failure
Step Check Yes No
1 CHECK IGNITION SYSTEM FOR SPARKS.
1) Remove the plug cord cap from each spark
plug.
2) Install the new spark plug on plug cord cap.
CAUTION:
Do not remove the spark plug from engine.
3) Contact the spark plug’s thread portion on
engine.
4) While opening the throttle valve fully, crank
the engine to check that spark occurs at each
cylinder.Does spark occur at each cyl-
inder?Check fuel pump
system. EN(H4SO)-67,
FUEL PUMP CIR-
CUIT, Diagnostics
for Engine Start-
ing Failure.>Go to step 2.
2 CHECK POWER SUPPLY CIRCUIT FOR IG-
NITION COIL & IGNITOR ASSY.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ignition coil
& ignitor ASSY.
3) Turn the ignition switch to ON.
4) Measure the power supply voltage between
ignition coil & ignitor ASSY connector and
engine ground.
Connector & terminal
(E12) No. 2 (+) — Engine ground (
−):Is the voltage more than 10 V? Go to step 3.Repair harness
and connector.
N
OTE:
In this case repair
the following:
 Open circuit in
harness between
ignition coil & igni-
tor ASSY, and
main relay connec-
tor
 Poor contact in
coupling connector
 Blown out fuse
3 CHECK HARNESS OF IGNITION COIL & IG-
NITOR ASSY GROUND CIRCUIT.
1) Turn the ignition switch to OFF.
2) Measure the resistance between ignition
coil & ignitor ASSY connector and engine
ground.
Connector & terminal
(E12) No. 3 — Engine ground:Is the resistance less than 5
Ω?Go to step 4.Repair harness
and connector.
N
OTE:
In this case repair
the following:
 Open circuit in
harness between
ignition coil & igni-
tor ASSY connec-
tor and engine
ground terminal
4 CHECK IGNITION COIL & IGNITOR ASSY.
1) Remove the spark plug cords.
2) Measure the resistance between spark
plug cord contact portions to check secondary
coil.
Te r m i n a l s
No. 1 — No. 2:
No. 3 — No. 4:Is the resistance 10 — 15 kΩ? Go to step 5.Replace the igni-
tion coil & ignitor
ASSY. IG(H4SO)-8, Igni-
tion Coil & Ignitor
Assembly.>
5 CHECK INPUT SIGNAL FOR IGNITION COIL
& IGNITOR ASSY.
1) Connect the connector to ignition coil &
ignitor ASSY.
2) Check if voltage varies synchronously with
engine speed when cranking, while monitoring
voltage between ignition coil & ignitor ASSY
connector and engine ground.
Connector & terminal
(E12) No. 1 (+) — Engine ground (
−):
(E12) No. 4 (+) — Engine ground (
−):Does the voltage vary more
than 10 V?Go to step 6.Replace the igni-
tion coil & ignitor
ASSY. IG(H4SO)-8, Igni-
tion Coil & Ignitor
Assembly.>

EN(H4SO)-68
ENGINE (DIAGNOSTIC)
Diagnostics for Engine Starting Failure
Step Check Yes No
1 CHECK OPERATING SOUND OF FUEL
PUMP.
Check that the fuel pump is in operation for two
seconds when turning the ignition switch to
ON.
N
OTE:
Fuel pump operation can also be executed us-
ing Subaru Select Monitor.
Refer to “Compulsory Valve Operation Check
Mode” for procedures. Compulsory Valve Operation Check Mode.>Does the fuel pump produce
operating sound?Check the fuel
injector circuit.
EN(H4SO)-70,
FUEL INJECTOR
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>Go to step 2.
2 CHECK GROUND CIRCUIT OF FUEL PUMP.
1) Turn the ignition switch to OFF.
2) Remove the fuel pump access hole lid.
3) Disconnect the connector from fuel pump.
4) Measure the resistance of harness connec-
tor between fuel pump and chassis ground.
Connector & terminal
(R58) No. 4 — Chassis ground:Is the resistance less than 5
Ω?Go to step 3.Repair harness
and connector.
N
OTE:
In this case repair
the following:
 Open circuit in
harness between
fuel pump connec-
tor and chassis
grounding terminal
 Poor contact in
coupling connector
3 CHECK POWER SUPPLY TO FUEL PUMP.
1) Turn the ignition switch to ON.
2) Measure the voltage of power supply circuit
between fuel pump connector and chassis
ground.
Connector & terminal
(R58) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10 V? Replace the fuel
pump. FU(H4SO)-55,
Fuel Pump.>Go to step 4.
4 CHECK HARNESS BETWEEN FUEL PUMP
AND FUEL PUMP RELAY CONNECTOR.
1) Turn the ignition switch to OFF.
2) Measure the resistance of harness connec-
tor between fuel pump and fuel pump relay.
Connector & terminal
(R58) No. 1 — (B46) No. 4:Is the resistance less than 1
Ω?Go to step 5.Repair harness
and connector.
N
OTE:
In this case repair
the following:
 Open circuit in
harness between
fuel pump connec-
tor and chassis
grounding terminal
 Poor contact in
coupling connector
5 CHECK HARNESS BETWEEN FUEL PUMP
AND FUEL PUMP RELAY CONNECTOR.
Measure the resistance of harness between
fuel pump and fuel pump relay connector.
Connector & terminal
(R58) No. 1 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 6.Repair short circuit
in harness
between fuel pump
and fuel pump
relay connector.
6 CHECK FUEL PUMP RELAY.
1) Disconnect the connectors from fuel pump
relay and main relay.
2) Remove the fuel pump relay and main relay
with bracket.
3) Connect the battery to fuel pump relay con-
nector terminals No. 1 and No. 3.
4) Measure the resistance between connector
terminals of fuel pump relay.
Te r m i n a l s
No. 2 — No. 4:Is the resistance less than 10
Ω?Go to step 7.Replace the fuel
pump relay. to FU(H4SO)-55,
Fuel Pump.>

EN(H4SO)-71
ENGINE (DIAGNOSTIC)
Diagnostics for Engine Starting Failure
Step Check Yes No
1 CHECK OPERATION OF EACH FUEL INJEC-
TOR.
While cranking the engine, check that each
fuel injector emits operating sound. Use a
sound scope or apply a screwdriver to the
injector for this check.Does the fuel pump emit oper-
ating sound?Check the fuel
pressure. ME(H4SO)-30,
INSPECTION,
Fuel Pressure.>Go to step 2.
2 CHECK POWER SUPPLY TO EACH FUEL
INJECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from fuel injector.
3) Turn the ignition switch to ON.
4) Measure the power supply voltage between
fuel injector terminal and engine ground.
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? Go to step 3.Repair harness
and connector.
N
OTE:
In this case repair
the following:
 Open circuit in
harness between
main relay and fuel
injector connector
 Poor contact in
main relay connec-
tor
 Poor contact in
coupling connector
 Poor contact in
fuel injector con-
nector
3 CHECK HARNESS BETWEEN ECM AND
FUEL INJECTOR CONNECTOR.
1) Disconnect the connector from ECM.
2) Measure the resistance of harness
between ECM and fuel injector connector.
Connector & terminal
#1 (B134) No. 34 — (E5) No. 1:
#2 (B134) No. 23 — (E16) No. 1:
#3 (B134) No. 22 — (E6) No. 1:
#4 (B134) No. 8 — (E17) No. 1:Is the resistance less than 1
Ω?Go to step 4.Repair harness
and connector.
N
OTE:
In this case repair
the following:
 Open circuit in
harness between
ECM and fuel
injector connector
 Poor contact in
coupling connector
4 CHECK HARNESS BETWEEN ECM AND
FUEL INJECTOR CONNECTOR.
Measure the resistance of harness between
ECM and fuel injector connector.
Connector & terminal
#1 (B134) No. 34 — Chassis ground:
#2 (B134) No. 23 — Chassis ground:
#3 (B134) No. 22 — Chassis ground:
#4 (B134) No. 8 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 5.Repair ground
short circuit in har-
ness between
ECM and fuel
injector connector.
5 CHECK EACH FUEL INJECTOR.
1) Turn the ignition switch to OFF.
2) Measure the resistance between each fuel
injector terminals.
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.
6 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair the poor
contact in ECM
connector.Inspection using
“General Diagnos-
tic Table” EN(H4SO)-255,
INSPECTION,
General Diagnos-
tic Table.>

EN(H4SO)-79
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
(B136) No. 6 — (B18) No. 3:
(B136) No. 17 — (B18) No. 3:Is the resistance less than 1
Ω?Go to step 2.Repair 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
(B136) No. 13 — (B18) No. 1:
(B136) No. 22 — (B18) No. 2:Is the resistance less than 1
Ω?Go to step 3.Repair 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. 4 — (B18) No. 4:Is the resistance less than 1
Ω?Go to step 4.Repair 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.
Te r m i n a l s
No. 3 — No. 4:Is the resistance less than 5
Ω?Go to step 5.Replace the front
oxygen (A/F) sen-
sor. FU(H4SO)-40,
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 poor con-
tact in ECM or
front oxygen (A/F)
sensor connector.Replace the front
oxygen (A/F) sen-
sor. FU(H4SO)-40,
Front Oxygen (A/
F) Sensor.>