2004 SUBARU FORESTER engine

SC(H4SO)-13
STARTING/CHARGING SYSTEM
Starter
7. PINION GAP
1) Measure the pinion gap while the pinion is pulled
out as shown in the figure.
Pinion gap:
0.5 — 2.0 mm (0.020 — 0.079 in)
If the motor is running with the pinion forced end-
wise on shaft, disconnect the connector from termi-
nal M of switch assembly, and then connect
terminal M to ground terminal (−) of battery with a
lead wire. Next, gently push the pinion back with
your fingertips, and then measure the pinion gap.
2) If the pinion gap is outside specified range, re-
move or add number of adjustment washers used
on the mounting surface of switch assembly until
correct pinion gap is obtained.
8. PERFORMANCE TEST
The starter should be submitted to performance
tests whenever it has been overhauled, to assure
its satisfactory performance when installed on the
engine.
Three performance tests, no-load test, load test,
and lock test, are presented here; however, if the
load test and lock test cannot be performed, carry
out at least the no-load test.
For these performance tests, use the circuit shown
in figure.
1) No-load test
With switch on, adjust the variable resistance to ob-
tain 11 V, take the ammeter reading, and then mea-
sure the starter speed. Compare these values with
the specifications.
No-load test (Standard):
Voltage / Current
MT model
MAX. 11 V / 95 A
AT model
MAX. 11 V / 90 A
Rotating speed
MT model
2,500 rpm or more
AT model
2,000 rpm or more
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within the specifications.
Load test (Standard):
Voltage / Load
MT model
7.5 V / 8.84 N (0.90 kgf, 1.99 lb)
AT model
7.7 V / 16.7 N (1.70 kgf, 3.75 lb)
(A) Pinion
(B) Pinion gap
(C) Stopper
SC-00027
(A) Variable resistance
(B) Starter body
(C) Magnetic switch
SC-00077
(A) (B)
(C)
12V +
AV
BS
M

FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
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(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)

ENGINE (DIAGNOSTIC)
EN(H4SO)
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 .................................................21
6. Engine Condition Data ..............................................................................24
7. Transmission Control Module (TCM) I/O Signal .......................................25
8. Data Link Connector .................................................................................26
9. OBD-II General Scan Tool ........................................................................27
10. Subaru Select Monitor...............................................................................29
11. Read Diagnostic Trouble Code (DTC) ......................................................36
12. Inspection Mode ........................................................................................37
13. Drive Cycle ................................................................................................42
14. Clear Memory Mode..................................................................................44
15. Compulsory Valve Operation Check Mode ...............................................45
16. Malfunction Indicator Light ........................................................................47
17. Diagnostics for Engine Starting Failure .....................................................57
18. List of Diagnostic Trouble Code (DTC) .....................................................72
19. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................78
20. General Diagnostic Table........................................................................255

EN(H4SO)-2
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
1. Basic Diagnostics Procedure
A: PROCEDURE
1. ENGINE
Step Check Yes No
1 CHECK ENGINE START FAILURE.
1) Ask the customer when and how the trou-
ble occurred using the interview check list.
List for Interview.>
2) Start the engine.Does the engine start? Go to step 2.Inspection using
“Diagnostics for
Engine Starting
Failure”. EN(H4SO)-57,
Diagnostics for
Engine Starting
Fai lu r e.>
2 CHECK ILLUMINATION OF MALFUNCTION
INDICATOR LIGHT.Does malfunction indicator
light illuminate?Go to step 3.Inspection using
“General Diagnos-
tic Table”. EN(H4SO)-255,
INSPECTION,
General Diagnos-
tic Table.>
3 CHECK INDICATION OF DTC ON DISPLAY
1) Turn the ignition switch to OFF.
2) Connect the Subaru Select Monitor or the
OBD-II general scan tool to data link connec-
tor.
3) Turn the ignition switch to ON and the Sub-
aru Select Monitor or OBD-II general scan tool
switch to ON.
4) Read the DTC on the Subaru Select Moni-
tor or OBD-II general scan tool.Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC?Record the DTC.
Repair the trouble
cause. EN(H4SO)-72, List
of Diagnostic Trou-
ble Code (DTC).>
Go to step 4.Repair the related
parts.
N
OTE:
If DTC is not shown
on display although
the engine warning
light illuminates, per-
form the diagnostics
of engine warning
light circuit or combi-
nation meter. to EN(H4SO)-47,
Malfunction Indica-
tor Light.>
4 PERFORM THE DIAGNOSIS.
1) Perform the Clear Memory Mode. EN(H4SO)-44, Clear Memory Mode.>
2) Perform the Inspection Mode. EN(H4SO)-37, Inspection Mode.>Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC?Check on “Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC)”
EN(H4SO)-78,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>Finish the diagno-
sis.

EN(H4SO)-3
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
2. AUTOMATIC TRANSMISSION
When the DTC about automatic transmission is
shown on display, carry out the following basic
check. After that, carry out the replacement or re-
pair work.
1) ATF level check Transmission Fluid.>
2) Differential gear oil level check Differential Gear Oil.>
3) ATF leak check Transmission Fluid.>
4) Differential gear oil level check Differential Gear Oil.>
5) Stall Test
6) Line Pressure Test sure Test.>
7) Transfer Clutch Pressure Test Transfer Clutch Pressure Test.>
8) Time Lag Test
9) Road Test
10) Shift characteristics Clutch Pressure Test.>

EN(H4SO)-4
ENGINE (DIAGNOSTIC)
Check List for Interview
2. Check List for Interview
A: INSPECTION
1. CHECK LIST No. 1
Check the following items when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customer’s name Engine No.
Date of sale Fuel brand
Date of repair
Odometer readingkm
V.I.N.miles
Weather❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Va r i o u s / O t h e r s :
Ambient air temperature°C (°F)
❏ Hot
❏ War m
❏ Cool
❏ Cold
Place❏ Highway
❏ Suburbs
❏ Inner city
❏ Uphill
❏ Downhill
❏ Rough road
❏ Others:
Engine temperature❏ Cold
❏ War ming-up
❏ After warming-up
❏ Any temperature
❏ Others:
Engine speed rpm
Vehicle speed km/h (MPH)
Driving conditions❏ Not affected
❏ At starting
❏ While idling
❏ At racing
❏ While accelerating
❏ While cruising
❏ While decelerating
❏ While turning (RH/LH)
Headlight❏ ON / ❏ OFF Rear defogger❏ ON / ❏ OFF
Blower❏ ON / ❏ OFF Audio❏ ON / ❏ OFF
A/C compressor❏ ON / ❏ OFF Car phone❏ ON / ❏ OFF
Radiator fan❏ ON / ❏ OFF
Fr o nt wi pe r❏ ON / ❏ OFF
Rear wiper❏ ON / ❏ OFF

EN(H4SO)-5
ENGINE (DIAGNOSTIC)
Check List for Interview
2. CHECK LIST No. 2
Check the following items about the vehicle’s state when malfunction indicator light turns on.
NOTE:
Use copies of this page for interviewing customers.
a) Other warning lights or indicators turn on. ❏ Yes / ❏ No
❏ Low fuel warning light
❏ Charge indicator light
❏ AT diagnostic indicator light
❏ ABS Warning light
❏ Oil pressure indicator light
b) Fuel level
 Lack of gasoline: ❏ Yes / ❏ No
 Indicator position of fuel gauge:
 Experienced running out of fuel: ❏ Ye s / ❏ No
c) Intentional connecting or disconnecting of harness connectors or spark plug cords: ❏ Yes / ❏ No
 What:
d) Intentional connecting or disconnecting of hoses: ❏ Ye s / ❏ No
 What:
e) Installing of other parts except genuine parts: ❏ Ye s / ❏ No
 What:
 Where:
f) Occurrence of noise: ❏ Yes / ❏ No
From where:
 What kind:
g) Occurrence of smell: ❏ Yes / ❏ No
From where:
 What kind:
h) Intrusion of water into engine compartment or passenger compartment: ❏ Yes / ❏ No
i) Troubles occurred
❏ Engine does not start.
❏ Engine stalls during idling.
❏ Engine stalls while driving.
❏ Engine speed decreases.
❏ Engine speed does not decrease.
❏ Rough idling
❏ Poor acceleration
❏ Back fire
❏ After fire
❏ Does not shift.
❏ Excessive shift shock

EN(H4SO)-6
ENGINE (DIAGNOSTIC)
General Description
3. General Description
A: CAUTION
1) Airbag system wiring harness is routed near the
ECM, main relay and fuel pump relay.
CAUTION:
 All air bag system wiring harnesses and con-
nectors are yellow. Do not use the electrical
test equipment on these circuits.
 Be careful not to damage the Airbag system
wiring harness when servicing the ECM, TCM,
main relay and fuel pump relay.
2) Never connect the battery in reverse polarity.
 The ECM will be destroyed immediately.
 The fuel injector and other part will be damaged.
3) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotive force will be generat-
ed in the generator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn the ignition
switch to OFF.
5) Poor contact has been identified as a primary
cause of this problem. Measure the voltage or re-
sistance of individual sensor or all electrical control
modules using a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the pin more
than 5 mm (0.20 in) into the part.
6) Remove the ECM from the located position after
disconnecting two cables on battery.
Otherwise, the ECM may be damaged.
CAUTION:
When replacing the ECM, be careful not to use
the wrong spec. ECM to avoid any damage on
the fuel injection system.
7) Connectors to each sensor in the engine com-
partment and the harness connectors on the en-
gine side and body side are all designed to be
waterproof. However, it is still necessary to take
care not to allow water to get into the connectors
when washing the vehicle, or when servicing the
vehicle on a rainy day.8) Use ECM mounting stud bolts as the grounding
point to body when measuring voltage and resis-
tance inside the passenger compartment.
9) Use engine ground terminal or engine proper as
the grounding point to body when measuring volt-
age and resistance in the engine compartment.
10) Use TCM mounting stud bolts as the grounding
point to body when measuring voltage and resis-
tance inside the passenger compartment.
11) Every MFI-related part is a precision part. Do
not drop them.
12) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
 The antenna must be kept as far apart as pos-
sible from the control unit. (The ECM is located
under the steering column, inside of the instru-
ment panel lower trim panel.)
(A) Stud bolt
(A) Stud bolt
EN-00001
(A)
EN-00153
EN-00154(A)