2004 SUBARU FORESTER ESP

ME(H4SO)-84
MECHANICAL
Cylinder Block
E: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage. Especial-
ly, inspect the important parts by means of red lead
check.
2) Check the oil passages for clogging.
3) Inspect the crankcase surface that mates with
cylinder head for warping by using a straight edge,
and correct by grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on cylinder
block’s front upper surface.
NOTE:
 Measurement should be performed at a temper-
ature 20°C (68°F).
 Standard sized pistons are classified into two
grades, “A” and “B”. These grades should be used
as a guide line in selecting a standard piston.Standard diameter:
2.0 L model
A: 92.005 — 92.015 mm (3.6222 — 3.6226
in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222
in)
2.5 L model
A: 99.505 — 99.515 mm (3.9175 — 3.9179
in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175
in)
2) How to measure the inner diameter of each cyl-
inder
Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights
shown in the figure, using a cylinder bore gauge.
NOTE:
Measurement should be performed at a tempera-
ture 20°C (68°F).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
(A) Main journal size mark
(B) Cylinder block RH-LH combination mark
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark
(F) #4 cylinder bore size mark
ME-00170 #5
#4
#3
#2
#1(A)(B)
(F)
(D)
A BA B
5 45 4
(C) (E)

CO(H4SO)-19
COOLING
Engine Coolant
3. Engine Coolant
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
1) Lift-up the vehicle.
2) Remove the under cover.
3) Remove the drain cock to drain engine coolant
into container.
NOTE:
Remove the radiator cap so that engine coolant will
drain faster.
4) Install the drain cock.
2. FILLING OF ENGINE COOLANT
1) Fill engine coolant into the radiator up to filler
neck position.
Coolant capacity (fill up to “FULL” level): to CO(H4SO)-2, SPECIFICATION, General De-
scription.>
NOTE:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crank-
case. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.
2) Fill engine coolant into the reservoir tank up to
Full level.
3) Warm-up the engine completely for more than 5
minutes at 2,000 to 3,000 rpm.
4) If the engine coolant level drops in radiator, add
engine coolant to filler neck position.5) If the engine coolant level drops from Full level of
reservoir tank, add engine coolant to Full level.
6) Attach the radiator cap and reservoir tank cap
properly.
CO-00009
CO-00010
FULLFULLLOWLOW

SC(H4SO)-2
STARTING/CHARGING SYSTEM
General Description
1. General Description
A: SPECIFICATION
Item Designation
StarterType Reduction type
Vehicle type MT model AT model
Model M000T30471 M000T20171
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (viewed from pinion gear side)
Number of pinion teeth 8 9
No-load charac-
teristicsVo l t a g e 1 1 V
Current 95 A or less 90 A or less
Rotating speed 2,500 rpm or more 2,000 rpm or more
Load character-
isticsVoltage 7.5 V 7.7 V
Current 300 A 400 A
Torque 8.84 N (0.90 kgf, 1.99 lb) or more 16.7 N (1.70 kgf, 3.75 lb) or more
Rotating speed 870 rpm or more 710 rpm or more
Lock character-
isticsVo l t a g e 4 V 3 . 5 V
Current 680 A or less 960 A or less
Torque 17 N (1.73 kgf, 12.5 lb) or more 31 N (3.16 kgf, 22.9 lb) or more
GeneratorTy p eRotating-field three-phase type, Voltage regulator built-in type, with load
response control system
ModelEC, EK model: A002TG0391
Other model: A002TB6991
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 90 A
Polarity on ground side Negative
Rotating direction Clockwise (viewed from pulley side)
Armature connection 3-phase Y-type
Output currentEC, EK model1,500 rpm — 40 A or more
2,500 rpm — 74 A or more
5,000 rpm — 84 A or more
Other model1,500 rpm — 36 A or more
2,500 rpm — 65 A or more
5,000 rpm — 86 A or more
Regulated voltage 14.1 — 14.8 V [20°C (68°F)]

EN(H4SO)-42
ENGINE (DIAGNOSTIC)
Drive Cycle
13.Drive Cycle
A: OPERATION
There are three driving patterns on diagnosis. Fol-
lowing trouble can be diagnosed with driving spec-
ified patterns. After repair the following trouble, be
sure to check that the trouble is cleared correctly by
the driving specified patterns.
1. PREPARATION FOR DRIVE CYCLE
1) Check battery voltage is more than 12 V and fuel
remains half [20 — 402 (5.3 — 10.6 US gal, 4.4 —
8.8 Imp gal)].2) After clearing the memory, check for any remain-
ing unresolved trouble data. 44, Clear Memory Mode.>
3) Separate the test mode connector.
NOTE:
 Be sure to perform the diagnosis after idling from
starting the cooled engine except when the engine
coolant temperature is specified.
 Perform the diagnosis twice when the DTC is
marked with *. After the completion of first diagno-
sis, stop the engine and perform the second diag-
nosis on same condition.
2. DRIVE THE VEHICLE 20 MINUTES AT THE SPEED OF 80 KM/H (50 MPH), AND THEN IDLE
THE ENGINE 1 MINUTE.
3. 10 MINUTES IDLING
NOTE:
Drive the vehicle more than 4 km/h (6 MPH) before diagnosis.
DTC Item On condition
*P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1) —
*P0111Intake Air Temperature Sensor Circuit Range/Per-
formance ProblemEngine coolant temperature at start is less than 30°C (86°F)
*P0125Insufficient coolant temperature for closed loop
fuel controlEngine coolant temperature at start is less than 20°C (68°F)
*P0130O
2 Sensor Circuit (Bank 1 Sensor 1)
—
*P0133O
2 Sensor Circuit Slow Response (Bank 1 Sensor
1)—
*P0420Catalyst System Efficiency Below Threshold
(Bank 1)—
P0459Evaporative Emission Control System Purge Con-
trol Valve Circuit High—
*P0461 Fuel Level Sensor Circuit Range/Performance —
*P0464 Fuel Level Sensor Circuit Intermittent —
*P1137O
2 Sensor Circuit (Bank 1 Sensor 1)
—
DTC Item On condition
*P0483 Cooling Fan Rationality Check —
*P0506 Idle Control System RPM Lower Than Expected —
*P0507 Idle Control System RPM Higher Than Expected —

EN(H4SO)-43
ENGINE (DIAGNOSTIC)
Drive Cycle
4. DRIVE THE VEHICLE WITH FOLLOWING DRIVE PATTERNS
(A) Run the engine at idle for a
minute.(D) Slowdown the vehicle to 64 km/h
(40 MPH) with throttle fully closed
condition.(F) Accelerate the vehicle to 97 km/h
(60 MPH) within 10 seconds.
(B) Accelerate the vehicle to 97 km/h
(60 MPH) within 20 seconds.(G) Stop the vehicle with throttle fully
closed condition. (E) Drive the vehicle at 64 km/h (40
MPH) for 10 seconds.
(C) Drive the vehicle at 97 km/h (60
MPH) for 20 seconds.
(1) Vehicle speed km/h (MPH) (2) Seconds
DTC Item On condition
*P0121 Throttle/Pedal Position Sensor/Switch “A” Circuit Range/Performance —
*P0139O
2 Sensor Circuit Slow Response (Bank 1 Sensor 2)
—
*P0171 System too Lean (Bank 1) —
*P0172 System too Rich (Bank 1) —
*P0301 Cylinder 1 Misfire Detected —
*P0302 Cylinder 2 Misfire Detected —
*P0303 Cylinder 3 Misfire Detected —
*P0304 Cylinder 4 Misfire Detected —
*P0400 Exhaust Gas Recirculation Flow —
EN-0019550
100150 0 65 (40) 96 (60)
(2) (1)

EN(H4SO)-73
ENGINE (DIAGNOSTIC)
List of Diagnostic Trouble Code (DTC)
P0130 O2 Sensor Circuit (Bank 1 Sensor 1) SOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0131 O
2 Sensor Circuit Low Voltage (Bank
1 Sensor 1) AGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0132 O
2 Sensor Circuit High Voltage
(Bank 1 Sensor 1) AGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0133 O
2 Sensor Circuit Slow Response
(Bank 1 Sensor 1) RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
P0134 O
2 Sensor Circuit No Activity
Detected (Bank 1 Sensor 1) DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
P0137 O
2 Sensor Circuit Low Voltage (Bank
1 Sensor 2) AGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0138 O
2 Sensor Circuit High Voltage
(Bank 1 Sensor 2) AGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0139 O
2 Sensor Circuit Slow Response
(Bank 1 Sensor 2) RESPONSE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
P0171 System Too Lean (Bank 1) nostic Procedure with Diagnostic Trouble Code (DTC).>
P0172 System Too Rich (Bank 1) nostic Procedure with Diagnostic Trouble Code (DTC).>
P0301 Cylinder 1 Misfire Detected Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0302 Cylinder 2 Misfire Detected Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0303 Cylinder 3 Misfire Detected Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0304 Cylinder 4 Misfire Detected Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0327 Knock Sensor 1 Circuit Low Input
(Bank 1 or Single Sensor) INPUT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0328 Knock Sensor 1 Circuit High Input
(Bank 1 or Single Sensor) INPUT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0335 Crankshaft Position Sensor “A” Cir-
cuit “A” CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0336 Crankshaft Position Sensor “A” Cir-
cuit Range/Performance “A” CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0340 Camshaft Position Sensor “A” Circuit
(Bank 1 or Single Sensor) CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0341 Camshaft Position Sensor “A” Circuit
Range/Performance (Bank 1 or Sin-
gle Sensor) CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
P0400 Exhaust Gas Recirculation Flow FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> DTC Item NOTE

EN(H4SO)-127
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
V: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
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 tion Mode.>.
WIRING DIAGRAM:
EN-02384
B18
3412
56
B47F44
12345678
B136B135
1234
B21
123
4
56
78
9
1011 12
1314 15 16
SBF-5
EE
B47
B18
6
4
5
3
2
1
B23 C13
C22C6 C17
C16
C5
8
B:
C:B135
B136
B21
E2 ECMBATTERY
B61F44
7
FRONT OXYGEN
(A/F) SENSOR MAIN RELAY
567
82 1
94
310
24
22 23251112131415
26 27
281617181920 21
5
2
84
3923 20 211011
221617
24
2512136
261915
14
1
7
18
LHDLHD
RHDRHD
4
3
1 2
B: C:

EN(H4SO)-137
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Z: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
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 tion Mode.>.
WIRING DIAGRAM:
EN-02385
BATTERYB61F44
7
B47 MAIN RELAY
12
35
46
B61
12345678
C4B14B19D15
C16C5
REAR
OXYGEN SENSOR
ECM
1432
8B21
B122
T6
E2
B47
T6B21
12 34
56 78
9
10 11 12
13 14 15 16
3456
12
1
B135 B:
D:
B137
SBF-5
C:B136
B122 : LHDB122 : RHDB137
4
1
53
2618 15 167891011
17 19
20121314
B135
567
82
94
310
24 22 23 251112131415
26 27
281617181920 21
B136
5
2
84
3923 20 211011
221617
24
2512136
261915
14
1
7
18
LHD
LHD
RHD
RHD1 8
4
143
T5
B19
2
B19T5
B122
T5
34
12
LHDLHD
RHDRHD
1234
123456781234
B:
D:C: