2004 SUBARU FORESTER fuel

EN(H4DOTC)-199
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
7 CHECK FUEL TANK CORD.
1) Disconnect the connector from fuel sub
level sensor.
2) Measure the resistance between fuel level
sensor and fuel sub level sensor.
Connector & terminal
(R58) No. 3 — (R59) No. 2:Is the resistance less than 10
Ω?Go to step 8.Repair open circuit
between fuel level
sensor and fuel
sub level sensor.
8 CHECK FUEL TANK CORD.
Measure the resistance between fuel sub level
sensor and coupler connector.
Connector & terminal
(R57) No. 2 — (R59) No. 1:Is the resistance less than 10
Ω?Go to step 9.Repair open circuit
between coupling
connector and fuel
sub level sensor.
9 CHECK FUEL LEVEL SENSOR.
1) Remove the fuel pump assembly. FU(H4DOTC)-62, Fuel Pump.>
2) While moving the fuel level sensor float up
and down, measure resistance between fuel
level sensor terminals.
Te r m i n a l s
No. 3 — No. 5:Is the resistance more than 53
Ω?Replace the fuel
level sensor. to FU(H4DOTC)-
64, Fuel Level
Sensor.>Go to step 10.
10 CHECK FUEL SUB LEVEL SENSOR.
1) Remove the fuel sub level sensor. FU(H4DOTC)-65, Fuel Sub Level Sensor.>
2) While moving the fuel sub level sensor float
up and down, measure resistance between
fuel sub level sensor terminals.
Te r m i n a l s
No. 1 — No. 2:Is the resistance more than 45
Ω?Replace the fuel
sub level sensor.
FU(H4DOTC)-65,
Fuel Sub Level
Sensor.>Replace the com-
bination meter.
Combination
Meter Assembly.> Step Check Yes No

EN(H4DOTC)-200
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
BC:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode ERATION, Clear Memory Mode.> and Inspection Mode .
WIRING DIAGRAM:
B72
R59R58
F60 : LHD
B21 : RHD
i10
B136
i11
1
23456789
10
R15
B136
ECM
i10
B38
B100F2F60E3
E2
B99
R3
i3
EE
E
RHD
RHD
LHD
FUEL
GAUGE
B :
i11 C :
C : B : COMBINATION
METER
B9 B10
C1
3*
*4
R15
R59
FUEL SUB
LEVEL SENSOR
R572
1
2R583
53
FUEL LEVEL
SENSOR
9
B21
16
16 20
3412
1213
4562123
4
56
78
9
1011 12
1314 15 16
F2LHD : 28
RHD : 20
LHD : 16
RHD : 2
*1
*2
LHD : 4
RHD : 3
LHD : 5
RHD : 17*3
*4
EN-02336
3412i3B98B37
B99
56
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35
1234567891011121314151617181920212223242526272829301234 5678910 11 12 13 14 15 16 17 18 19 20123
45678
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
2534
12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 2456 7
: LHDB98
: RHD
: LHD
R2
: RHD
1*2*
B37
i223
IGNITION SWITCH
SBF-4SBF-1
B72
14
E
No.14
RHD
B38
i316
LHD
LHD
RHDBATTERY

EN(H4DOTC)-201
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
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)”. EN(H4DOTC)-74,
List of Diagnostic
Trouble Code
(DTC).>Go to step 2.
2 CHECK FUEL LEVEL SENSOR.
1) Remove the fuel pump assembly. FU(H4DOTC)-62, Fuel Pump.>
2) While moving the fuel level sensor float up
and down, make sure that the resistance
between fuel level sensor terminals changes
smoothly.
Te r m i n a l s
No. 3 — No. 5:Does the resistance change
smoothly between approx. 0.5
— 52 Ω?Go to step 3.Replace the fuel
level sensor. to FU(H4DOTC)-
64, Fuel Level
Sensor.>
3 CHECK FUEL SUB LEVEL SENSOR.
1) Remove the fuel sub level sensor. FU(H4DOTC)-65, Fuel Sub Level Sensor.>
2) While moving the fuel sub level sensor float
up and down, make sure that the resistance
between fuel level sensor terminals changes
smoothly.
Te r m i n a l s
No. 1 — No. 2: Does the resistance change
smoothly between approx. 0.5
— 44 Ω?Repair poor con-
tact in ECM, com-
bination meter and
coupling connec-
tors.Replace the fuel
sub level sensor.
FU(H4DOTC)-65,
Fuel Sub Level
Sensor.>

EN(H4DOTC)-219
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
BL:DTC P0519 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE)
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
 Engine keeps running at higher revolution than specified idling revolution.
 Fuel is cut according to fail-safe function.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode ERATION, Clear Memory Mode.> and Inspection Mode .
WIRING DIAGRAM:
EN-02339
BATTERY MAIN RELAY
EE
7 6
4
5
3
2
1RHD
RHDLHD LHD
27
IDLE
AIR CONTROL
SOLENOID
VALVE
1
3
E7
B47
B4734
12
56
F44
12345678
B134
F44B61
B134
ECM
2
1
RHD
RHD
LHD LHD
B100
F2
F60B21
E3
15
SBF-5
: LHD : RHD
F60
B22 : LHD
: RHD
E7
123
125678
131415169101112
34
17181920
123
4
56
78
9
1011 12
1314 15 16
F74
F61
B21 : LHD
: RHDRHD RHD
E3
B2212
LHD
LHD
12
E2
F61
F74
B200
34
128910 11
12 13 14 15 16 17 18 19 20 21 22 23 2456 7
F2
1234 5678910 11 12 13 14 15 16 17 18 19 20
E2
: LHD : RHD
20
56 7
82 1
94 310
24 22 23 25 11 12 13 14 15
26 27
2816 17
18 19 20 21
33 34 29
32 30 31

EN(H4DOTC)-295
ENGINE (DIAGNOSTIC)
General Diagnostic Table
20.General Diagnostic Table
A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. General.>
Symptom Problem parts
1. Engine stalls during idling.1) Idle air control solenoid valve
2) Manifold absolute pressure sensor
3) Mass air flow and intake air temperature sensor
4) Ignition parts (*1)
5) Engine coolant temperature sensor (*2)
6) Crankshaft position sensor (*3)
7) Camshaft position sensor (*3)
8) Fuel injection parts (*4)
2. Rough idling1) Idle air control solenoid valve
2) Manifold absolute pressure sensor
3) Mass air flow and intake air temperature sensor
4) Engine coolant temperature sensor (*2)
5) Ignition parts (*1)
6) Air intake system (*5)
7) Fuel injection parts (*4)
8) Throttle position sensor
9) Crankshaft position sensor (*3)
10) Camshaft position sensor (*3)
11) Oxygen sensor
12) Fuel pump and fuel pump relay
3. Engine does not return to idle.1) Idle air control solenoid valve
2) Engine coolant temperature sensor
3) Accelerator cable (*6)
4) Throttle position sensor
5) Manifold absolute pressure sensor
6) Mass air flow sensor
4. Poor acceleration1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Throttle position sensor
4) Fuel injection parts (*4)
5) Fuel pump and fuel pump relay
6) Engine coolant temperature sensor (*2)
7) Crankshaft position sensor (*3)
8) Camshaft position sensor (*3)
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
11) Ignition parts (*1)
5. Engine stalls or engine sags or hesitates at
acceleration.1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor (*2)
4) Crankshaft position sensor (*3)
5) Camshaft position sensor (*3)
6) Purge control solenoid valve
7) Fuel injection parts (*4)
8) Throttle position sensor
9) Fuel pump and fuel pump relay

EN(H4DOTC)-296
ENGINE (DIAGNOSTIC)
General Diagnostic Table
*1: Check ignition coil & ignitor ASSY and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
*6: Adjust accelerator cable. 6. Surging1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor (*2)
4) Crankshaft position sensor (*3)
5) Camshaft position sensor (*3)
6) Fuel injection parts (*4)
7) Throttle position sensor
8) Fuel pump and fuel pump relay
7. Spark knock1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor
4) Knock sensor
5) Fuel injection parts (*4)
6) Fuel pump and fuel pump relay
8. After burning in exhaust system1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor (*2)
4) Fuel injection parts (*4)
5) Fuel pump and fuel pump relay Symptom Problem parts

FUJI HEAVY INDUSTRIES LTD. G8080GE4
2004 FORESTER 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 SYSTEM) FU(H4DOTC 2.5)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC 2.5)
INTAKE (INDUCTION) IN(H4DOTC 2.5)
MECHANICAL ME(H4DOTC 2.5)
EXHAUST EX(H4DOTC 2.5)
COOLING CO(H4DOTC 2.5)
LUBRICATION LU(H4DOTC 2.5)
SPEED CONTROL SYSTEM SP(H4DOTC 2.5)
IGNITION IG(H4DOTC 2.5)
STARTING/CHARGING SYSTEM SC(H4DOTC 2.5)
ENGINE (DIAGNOSTIC) EN(H4DOTC 2.5)

FUEL INJECTION (FUEL SYSTEM)
FU(H4DOTC 2.5)
Page
1. General Description ....................................................................................2
2. Throttle Body .............................................................................................13
3. Intake Manifold ..........................................................................................14
4. Engine Coolant Temperature Sensor........................................................26
5. Crankshaft Position Sensor.......................................................................27
6. Camshaft Position Sensor.........................................................................28
7. Knock Sensor ............................................................................................29
8. Mass Air Flow and Intake Air Temperature Sensor ..................................30
9. Manifold Absolute Pressure Sensor ..........................................................31
10. Fuel Injector ..............................................................................................32
11. Tumble Generator Valve Assembly ..........................................................33
12. Tumble Generator Valve Actuator.............................................................34
13. Wastegate Control Solenoid Valve ...........................................................35
14. Front Oxygen (A/F) Sensor .......................................................................36
15. Rear Oxygen Sensor.................................................................................38
16. Exhaust Temperature Sensor ...................................................................40
17. Engine Control Module (ECM) ..................................................................41
18. Main Relay ................................................................................................42
19. Fuel Pump Relay.......................................................................................43
20. Fuel Pump Control Unit .............................................................................44
21. Fuel ...........................................................................................................45
22. Fuel Tank ..................................................................................................46
23. Fuel Filler Pipe ..........................................................................................48
24. Fuel Pump .................................................................................................52
25. Fuel Level Sensor .....................................................................................54
26. Fuel Sub Level Sensor ..............................................................................55
27. Fuel Filter ..................................................................................................57
28. Fuel Cut Valve...........................................................................................58
29. Fuel Damper Valve ...................................................................................59
30. Fuel Delivery, Return and Evaporation Lines............................................60
31. Fuel System Trouble in General ...............................................................63