2004 SUBARU FORESTER replace disc

EN(H4DOTC 2.5)-146
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK SPEEDOMETER AND TACHOME-
TER OPERATION IN COMBINATION
METER.Does the speedometer and
tachometer operate normally?Go to step 2.Repair or replace
the combination
meter. 3, Combination
Meter System.>
2 CHECK INPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON. (engine
OFF)
2) Measure the voltage between ECM con-
nector and chassis ground.
Connector & terminal
(B136) No. 20 (+) — Chassis ground (
−):Is the voltage less than 0.12
V?Go to step 4.Go to step 3.
3 CHECK INPUT SIGNAL FOR ECM WITH
SUBARU SELECT MONITOR.
Read the data of fuel level sensor signal using
Subaru Select Monitor.
N
OTE:
 Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. 2.5)-27, Subaru Select Monitor.>Does the voltage change by
shaking the ECM harness and
connector?Repair the poor
contact in ECM
connector.Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. A tempo-
rary poor contact
of the connector
may be the cause.
NOTE:
In this case repair
the following:
 Poor contact in
combination meter
connector
 Poor contact in
ECM connector.
 Poor contact in
coupling connector
4 CHECK INPUT VOLTAGE OF ECM.
1) Turn the ignition switch to OFF.
2) Separate fuel tank cord connector (R57)
and rear wiring harness connector (R15).
3) Turn the ignition switch to ON.
4) Measure the voltage of harness between
ECM connector and chassis ground.
Connector & terminal
(B136) No. 20 (+) — Chassis ground (
−):Is the voltage more than 0.12
V?Go to step 5.Go to step 6.
5 CHECK HARNESS BETWEEN ECM AND
COMBINATION METER.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from connector
(i10), (i11) and ECM connector.
3) Measure the resistance between ECM and
chassis ground.
Connector & terminal
(B136) No. 20 — Chassis ground:Is the resistance
more than 1 MΩ?Go to step 7.Repair the ground
short in harness
between ECM and
combination meter
connector.
6 CHECK HARNESS BETWEEN ECM AND
COMBINATION METER.
Measure the resistance between ECM and
combination meter connector.
Connector & terminal
(B136) No. 20 — (i11) No. 1:Is the resistance less than 10
Ω?Repair or replace
the combination
meter. 3, Combination
Meter System.>Repair open circuit
between ECM and
combination meter
connector.
NOTE:
In this case repair
the following:
Poor contact in
coupling connector

EN(H4DOTC 2.5)-147
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
7 CHECK FUEL TANK CORD.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from fuel sub
level sensor.
3) Measure the resistance between fuel sub
level sensor and chassis ground.
Connector & terminal
(R59) No. 1 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 8.Repair ground
short circuit in fuel
tank cord.
8 CHECK FUEL TANK CORD.
1) Disconnect the connector from fuel pump
assembly.
2) Measure the resistance between fuel pump
assembly and chassis ground.
Connector & terminal
(R59) No. 2 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 9.Repair ground
short circuit in fuel
tank cord.
9 CHECK FUEL LEVEL SENSOR.
1) Remove the fuel pump assembly. FU(H4DOTC)-62, Fuel Pump.>
2) Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Te r m i n a l s
No. 2 — No. 3:Is the resistance 0.5 — 2.5 Ω? Go to step 10.Replace the fuel
level sensor.
10 CHECK FUEL SUB LEVEL SENSOR.
1) Remove the fuel sub level sensor. FU(H4DOTC 2.5)-55, Fuel Sub Level Sensor.>
2) Measure the resistance between fuel sub
level sensor and terminals with its float set to
the full position.
Te r m i n a l s
No. 1 — No. 2:Is the resistance 0.5 — 2.5 Ω? Repair poor con-
tact in harness
between ECM and
combination meter
connector.Replace the fuel
sub level sensor. Step Check Yes No

EN(H4DOTC 2.5)-149
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK SPEEDOMETER AND TACHOME-
TER OPERATION IN COMBINATION
METER.Does the speedometer and
tachometer operate normally?Go to step 2.Repair or replace
the combination
meter. 3, Combination
Meter System.>
2 CHECK INPUT SIGNAL FROM ECM.
1) Turn the ignition switch to ON. (engine OFF)
2) Measure the voltage between ECM con-
nector and chassis ground.
Connector & terminal
(B136) No. 20 (+) — Chassis ground (
−):Is the voltage more than 4.75
V?Go to step 3.Even if the malfunc-
tion indicator light
illuminates, the cir-
cuit has returned to
a normal condition
at this time. A tem-
porary poor contact
of the connector
may be the cause.
N
OTE:
In this case repair
the following:
 Poor contact in
fuel pump connec-
tor
 Poor contact in
coupling connector
3 CHECK INPUT VOLTAGE OF ECM.
1) Turn the ignition switch to OFF.
2) Disconnect the combination meter connec-
tor (i11) and ECM connector.
3) Turn the ignition switch to ON.
4) Measure the voltage of harness between
ECM and chassis ground.
Connector & terminal
(B136) No. 20 (+) — Chassis ground (
−):Is the voltage more than 4.75
V?Go to step 4.Repair battery
short circuit
between ECM and
combination meter
connector.
4 CHECK HARNESS BETWEEN ECM AND
FUEL TANK CORD.
1) Turn the ignition switch to OFF.
2) Separate fuel tank cord connector (R57)
and rear wiring harness connector (R15).
3) Measure the resistance between ECM and
fuel tank cord.
Connector & terminal
(B136) No. 20 — (R15) No. 7:Is the resistance less than 5
Ω?Go to step 5.Repair open circuit
between ECM and
fuel tank cord.
5 CHECK HARNESS BETWEEN FUEL TANK
CORD AND CHASSIS GROUND.
Measure the resistance between fuel tank cord
and chassis ground.
Connector & terminal
(R15) No. 3 — Chassis ground:Is the resistance less than 5
Ω?Go to step 6.Repair open circuit
between fuel tank
cord and chassis
ground.
N
OTE:
In this case repair
the following:
Poor contact in
coupling connector
6 CHECK FUEL TANK CORD.
1) Disconnect the connector from fuel level
sensor.
2) Measure the resistance between fuel level
sensor and coupler connector.
Connector & terminal
(R57) No. 3 — (R58) No. 5:Is the resistance less than 10
Ω?Go to step 7.Repair open circuit
between coupling
connector and fuel
level sensor.

EN(H4DOTC 2.5)-150
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.

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. 2 — No. 3:Is the resistance more than 53
Ω?Replace the fuel
level sensor. to FU(H4DOTC
2.5)-54, Fuel Level
Sensor.>Go to step 10.
10 CHECK FUEL SUB LEVEL SENSOR.
1) Remove the fuel sub level sensor. FU(H4DOTC 2.5)-55, 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 2.5)-
55, Fuel Sub Level
Sensor.>Replace the com-
bination meter.
Combination
Meter Assembly.> Step Check Yes No

EN(H4DOTC 2.5)-152
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND ECM CONNECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from vehicle
speed sensor ECM.
3) Measure the resistance of harness
between vehicle speed sensor connector and
chassis ground.
Connector & terminal
(B17) No. 1 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 2.Repair ground short
circuit in harness
between vehicle
speed sensor and
ECM connector.
2 CHECK POOR CONTACT.
Check poor contact in vehicle speed sensor
connector.Is there poor contact in vehicle
speed sensor connector?Repair poor con-
tact in vehicle
speed sensor con-
nector.Replace the vehi-
cle speed sensor.
Vehicle Speed
Sensor.>

EN(H4DOTC 2.5)-159
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 2.5)-
65, List of Diag-
nostic Trouble
Code (DTC).>
N
OTE:
In this case, it is
not necessary to
inspect DTC
P0519.Go to step 2.
2 CHECK AIR INTAKE SYSTEM.
1) Turn the ignition switch to ON.
2) Start and idle the engine.
3) Check the following items:
 Loose installation of intake manifold and
throttle body
 Cracks of intake manifold gasket and throttle
body gasket
 Disconnections of vacuum hosesIs there any fault in air intake
system?Repair air suction
and leaks.Go to step 3.
3 CHECK ELECTRONIC THROTTLE CON-
TROL.
1) Turn the ignition switch to OFF.
2) Replace the electronic throttle control.
3) Check the electronic throttle control.Are foreign matters found
inside the electronic throttle
control?Remove foreign
matters from the
electronic throttle
control.Perform the diag-
nosis of DTC
P2101.

EN(H4DOTC 2.5)-161
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK CURRENT DATA.
1) Start the engine.
2) Read the data of exhaust temperature sen-
sor signal using Subaru Select Monitor or
OBD-II general scan tool.
N
OTE:
 Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. 2.5)-27, Subaru Select Monitor.>
 OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.Is the temperature more than
1,200°C (2,192°F)?Go to step 2.Repair the poor
contact.
N
OTE:
In this case repair
the following:
 Poor contact of
exhaust tempera-
ture sensor
 Poor contact in
ECM
 Poor contact in
joint connector
2 CHECK HARNESS BETWEEN EXHAUST
TEMPERATURE SENSOR AND ECM CON-
NECTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from exhaust
temperature sensor.
3) Turn the ignition switch to ON.
4) Read the data of exhaust temperature sen-
sor signal using Subaru Select Monitor or
OBD-II general scan tool.
N
OTE:
 Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. 2.5)-27, Subaru Select Monitor.>
 OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.Is the temperature less than
372°C (702°F)?Replace the
exhaust tempera-
ture sensor. to FU(H4DOTC
2.5)-40, Exhaust
Temperature Sen-
sor.>Repair ground
short circuit in har-
ness between
exhaust tempera-
ture sensor and
ECM connector.

EN(H4DOTC 2.5)-166
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK HARNESS BETWEEN ECM AND
TCM.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from ECM.
3) Disconnect the connectors from TCM.
4) Measure the resistance between ECM and
TCM connectors.
Connector & terminal
(B137) No. 18 — (B55) No. 3:
(B137) No. 26 — (B55) No. 12:Is the resistance less than 1
Ω?Go to step 2.Repair the harness
and connector.
2 CHECK HARNESS BETWEEN ECM AND
TCM.
Measure the resistance between ECM connec-
tor and chassis ground.
Connector & terminal
(B137) No. 18 — Chassis ground:
(B137) No. 26 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 3.Repair the harness
and connector.
3 CHECK HARNESS BETWEEN ECM AND
TCM.
Check the resistance between ECM connec-
tors.
Connector & terminal
(B137) No. 18 — (B137) No. 26:Is the resistance more than 1
MΩ?Go to step 4.Repair the harness
and connector.
4 CHECK AT SYSTEM CONDITION.
Perform the diagnosis for AT using Subaru
Select Monitor.Is DTC P1718 displayed? Check AT system. Replace the ECM.