2004 SUBARU FORESTER ignition

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)

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)

EN(H4DOTC 2.5)-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.
Check List for Interview.>
2) Start the engine.Does the engine start? Go to step 2.Inspection using
“Diagnostics for
Engine Start Fail-
ure”. EN(H4DOTC 2.5)-
54, 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(H4DOTC 2.5)-
258, General Diag-
nostic 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(H4DOTC 2.5)-
65, List of Diag-
nostic Trouble
Code (DTC).> Go
to step 4.Repair the related
parts.
N
OTE:
If DTC is not shown
on display although
the malfunction in-
dicator light illumi-
nates, perform the
diagnostics for mal-
function indicator
light circuit or com-
bination meter.
EN(H4DOTC 2.5)-
45, Malfunction In-
dicator Light.>
4 PERFORM THE DIAGNOSIS.
1) Perform clear memory mode. EN(H4DOTC 2.5)-42, Clear Memory Mode.>
2) Perform the “INSPECTION MODE”. to EN(H4DOTC 2.5)-35, Inspection Mode.>Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC?Check on “Diag-
nostic Chart with
Diagnostic Trou-
ble Code (DTC)”.
EN(H4DOTC 2.5)-
70, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>Finish the diagno-
sis.

EN(H4DOTC 2.5)-13
ENGINE (DIAGNOSTIC)
Electrical Component Location
 SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM
PARTS
(1) Wastegate control solenoid valve (3) Ignition coil (5) Oil flow control solenoid valve
(4) Tumble generator valve actuator (2) Purge control solenoid valve (6) Injector
EN-00310 (1)EN-00311 (2)
EN-02411
(4)(4) (1)
(5)(5)(3)(6)(2)(3)(5)(6)

EN(H4DOTC 2.5)-17
ENGINE (DIAGNOSTIC)
Engine Control Module (ECM) I/O Signal
5. Engine Control Module (ECM) I/O Signal
A: ELECTRICAL SPECIFICATION
DESCRIPTION Connector No. Terminal No.Signal (V)
NOTE
Ignition SW ON
(engine OFF)Engine ON
(Idling)
Crank-
shaft posi-
tion sensorSignal (+) B135 10 0−7 — +7 Waveform
Signal (−) B135 22 0 0 —
Shield B135 31 0 0 —
Rear oxy-
gen sensorSignal B137 25 0 0 — 0.9 —
Shield B137 31 0 0 —
GND
(sensors)B136 35 0 0 —
Fr o nt ox y-
gen (A/F)
sensor
heaterSignal 1 B134 3 0 — 1.0 — Waveform
Signal 2 B134 2 0 — 1.0 — Waveform
Rear oxygen sensor
heater signalB135 2 0 — 1.0 — Waveform
Engine
coolant
tempera-
ture sen-
sorSignal B136 14 1.0 — 1.4 1.0 — 1.4 After engine is warmed-up.
GND
(sensors)B136 35 0 0 After engine is warmed-up.
Vehicle speed signal B135 26 0 or 5 0 or 5“5” and “0” are repeatedly dis-
played when vehicle is driven.
Air flow
sensorSignal B136 23 — 0.3 — 4.5 —
Shield B136 32 0 0 —
GND B136 31 0 0 —
Intake air temperature
sensor signalB136 13 0.3 — 4.6 0.3 — 4.6 —
Exhaust
gas tem-
perature
sensorSignal B136 24 — — —
GND
(sensors)B136 35 0 0 —
EN-01812
B134
5 6 7
8 21
9 43
10
24 2223 2511 12 13 14 15
26 27
28 16 17
18 19 20 21
33 34 29
32 3031
B136
5 6
7 8 21
9 43
10
24 2223 2511 12 13
14 15
26 27
28 16
17 18 19 20 21
33 3429
3230
31 35
B135
5 6 7
8 21
9 43
10
24 2223 2511 12 13 14 15
26 27
28 16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8 21
9 43
10
22 2311 12 13 14 15
24 25
26 16 17
18 19 20 21
27 28 29 30 31
To
To To
To

EN(H4DOTC 2.5)-18
ENGINE (DIAGNOSTIC)
Engine Control Module (ECM) I/O Signal
Tu m b l e
generator
valve posi-
tion sen-
sor RHSignal B136 27Fully closed: 3.8 — 4.9
Fully opened: 0.2 — 0.9—
Pow er
supplyB136 16 5 5 —
GND
(sensor)B136 35 0 0 —
Tu m b l e
generator
valve posi-
tion sen-
sor LHSignal B136 26Fully closed: 3.8 — 4.9
Fully opened: 0.2 — 0.9—
Pow er
supplyB136 16 5 5 —
GND
(sensor)B136 35 0 0 —
Tumble generator valve
RH (open)B134 9 0 or 10 — 13 0 or 13 — 14 Waveform
Tumble generator valve
RH (close)B134 8 0 or 10 — 13 0 or 13 — 14 Waveform
Tumble generator valve
LH (open)B134 11 0 or 10 — 13 0 or 13 — 14 Waveform
Tumble generator valve
LH (close)B134 10 0 or 10 — 13 0 or 13 — 14 Waveform
Wastegate control sole-
noid valveB134 32 0 or 10 — 13 0 or 13 — 14 Waveform
Starter switch B137 8 0 0 Cranking: 8 — 14
A/C switch B137 17ON: 10 — 13
OFF: 0ON: 13 — 14
OFF: 0—
Ignition switch B137 16 10 — 13 13 — 14 —
Neutral Position Switch B137 9ON: 10 — 13
OFF: 0ON: 13 — 14
OFF: 0—
Test Mode Connector B137 15 10 — 13 13 — 14 When connected: 0
Knock
sensorSignal B136 25 2.8 2.8 —
Shield B136 33 0 0 —
Back-up power supply B135 19 10 — 13 13 — 14 Ignition switch “OFF”: 10 — 13
Control module power
supplyB135 5 10 — 13 13 — 14 —
B135 6 10 — 13 13 — 14 —
Sensor power supply B136 16 5 5 —
Ignition
control#1 B135 18 0 13 — 14 Waveform
#2 B135 17 0 13 — 14 Waveform
#3 B135 16 0 13 — 14 Waveform
#4 B135 15 0 13 — 14 Waveform
Fuel injec-
tor#1 B136 6 10 — 13 1 — 14 Waveform
#2 B136 5 10 — 13 1 — 14 Waveform
#3 B136 4 10 — 13 1 — 14 Waveform
#4 B136 3 10 — 13 1 — 14 Waveform
Fuel pump
control unitDiagnosis
signalB137 28 0 or 5 0 or 5 Waveform
Control
signalB135 27 10 — 13 13 — 14 —
A/C relay control B135 33ON: 0.5, or less
OFF: 10 — 13ON: 0.5, or less
OFF: 13 — 14—
Radiator fan relay 1 con-
trolB135 25ON: 0.5, or less
OFF: 10 — 13ON: 0.5, or less
OFF: 13 — 14— DESCRIPTION Connector No. Terminal No.Signal (V)
NOTE
Ignition SW ON
(engine OFF)Engine ON
(Idling)

EN(H4DOTC 2.5)-19
ENGINE (DIAGNOSTIC)
Engine Control Module (ECM) I/O Signal
Radiator fan relay 2 con-
trolB135 24ON: 0.5, or less
OFF: 10 — 13ON: 0.5, or less
OFF: 13 — 14Model with A/C only
Malfunction indicator
lightB134 17 — —Light “ON”: 1, or less
Light “OFF”: 10 — 14
Engine speed output B134 23 — 0 — 13, or more Waveform
Purge control solenoid
valveB134 14ON: 1, or less
OFF: 10 — 13ON: 1, or less
OFF: 13 — 14Wavefor m
Manifold
absolute
pressure
sensorSignal B136 22 1.7 — 2.4 1.1 — 1.6
— Pow er
supplyB136 16 5 5
GND
(sensors)B136 35 0 0
Small light switch B137 12ON: 0
OFF: 10 — 13ON: 0
OFF: 13 — 14—
Blower fan switch B137 13ON: 0
OFF: 10 — 13ON: 0
OFF: 13 — 14—
Rear defogger switch B137 11ON: 0
OFF: 10 — 13ON: 0
OFF: 13 — 14—
Power steering oil pres-
sure switchB137 10 10 — 13ON: 0
OFF: 13 — 14—
Front oxygen (A/F) sen-
sor signal (+)B134 33 2.8 — 3.2 2.8 — 3.2 —
Front oxygen (A/F) sen-
sor signal (−)B134 26 2.4 — 2.7 2.4 — 2.7 —
Front oxygen (A/F) sen-
sor shieldB134 25 0 0 —
SSM/GST communica-
tion lineB137 20 1 ← → 41 ← → 4—
GND (injector) B137 7 0 0 —
GND (ignition system) B135 12 0 0 —
GND (power supply)B135 4 0 0 —
B135 1 0 0 —
GND (control system)B137 1 0 0 —
B137 2 0 0 —
GND (Front oxygen (A/F)
sensor heater 1)B134 7 0 0 —
GND (Front oxygen (A/F)
sensor heater 2)B134 6 0 0 —
Camshaft position sen-
sor (LH)B135 8 0 — 0.9ON: 0
OFF: 4.7 — 5.3Wavefor m
Camshaft position sen-
sor (RH)B135 9 0 — 0.9ON: 0
OFF: 4.7 — 5.3Wavefor m
Fuel level sensor B136 20 0.12 — 4.75 0.12 — 4.75 —
Electronic
throttle
controlMain B136 180.64 — 0.72
Fully opens:
3.960.64 — 0.72
(After engine is
warmed-up.)Fully closed: 0.6 Fully opens:
3.96
Sub B136 291.51 — 1.58
Fully opens:
4.171.51 — 1.58
(After engine is
warmed-up)Fully closed: 1.48 Fully opens:
4.17
Pow er
supplyB136 16 5 5 —
GND
(sensor)B137 3 0 0 — DESCRIPTION Connector No. Terminal No.Signal (V)
NOTE
Ignition SW ON
(engine OFF)Engine ON
(Idling)

EN(H4DOTC 2.5)-20
ENGINE (DIAGNOSTIC)
Engine Control Module (ECM) I/O Signal
Electronic throttle con-
trol motor (+)B137 5 Duty waveform Duty waveform Drive frequency: 500 Hz
Electronic throttle con-
trol motor (−)B137 4 Duty waveform Duty waveform Drive frequency: 500 Hz
Electronic throttle con-
trol motor power supplyB137 6 10 — 13 13 — 14 —
Electronic throttle con-
trol motor relayB135 35ON: 0
OFF: 10 — 13ON: 0
OFF: 13 — 14When ignition switch is turned to
ON: ON
Oil flow
control
solenoid
(LH)Signal (+) B134 19ON: 10 — 13
OFF: 0ON: 13 — 14
OFF: 0—
Signal (−) B134 29 0 0 —
Oil flow
control
solenoid
(RH)Signal (+) B134 18ON: 10 — 13
OFF: 0ON: 13 — 14
OFF: 0—
Signal (−) B134 28 0 0 —
Accelera-
tor Pedal
Po si ti o n
SensorMain B136 17Fully closed: 1
Fully opens: 3.5Fully closed: 1
Fully opens: 3.5—
Pow er
supplyB136 15 5 5 —
GND
(sensor)B136 34 0 0 —
Sub B136 28Fully closed: 1
Fully opens: 3.5Fully closed: 1
Fully opens: 3.5—
Main light B134 15ON: 0
OFF: 10 — 13ON: 0
OFF: 13 — 14—
Clutch switch B134 1When clutch
pedal is
depressed: 0
When clutch
pedal is
released: 10 —
13When clutch
pedal is
depressed: 0
When clutch
pedal is
released: 13 —
14—
SET/COAST switch B136 11ON: 10 — 13
OFF: 0ON: 13 — 14
OFF: 0—
Brake switch 1 B136 9When brake
pedal is
depressed: 0
When brake
pedal is
released: 10 —
13When brake
pedal is
depressed: 0
When brake
pedal is
released: 13 —
14—
Brake switch 2 B136 8When brake
pedal is
depressed: 10
— 13
When brake
pedal is
released: 0When brake
pedal is
depressed: 13
— 14
When brake
pedal is
released: 0—
RESUME/ACCEL
switchB136 10ON: 10 — 13
OFF: 0ON: 13 — 14
OFF: 0—
Main switch B136 7ON: 10 — 13
OFF: 0ON: 13 — 14
OFF: 0—
CAN Com-
municationSignal (+) B137 18 Pulse signal —
Signal (−) B137 26 Pulse signal — DESCRIPTION Connector No. Terminal No.Signal (V)
NOTE
Ignition SW ON
(engine OFF)Engine ON
(Idling)