SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC)-6
FUEL INJECTION (FUEL SYSTEM)
General Description
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
(1) Crankshaft position sensor (4) AVCS camshaft position sensorTightening torque: N⋅m (kgf-m, ft-lb)
(2) Knock sensorT1: 6.4 (0.65, 4.7)
(3) Camshaft position sensorT2: 24 (2.4, 17.4)
FU-00003
T1
(4)
T1
T1T2
T1
(4)
(2)(3)
(1)

FU(H4DOTC)-7
FUEL INJECTION (FUEL SYSTEM)
General Description
4. FUEL TANK
FU-00909
T1
T1
T3
T2
T2
T2
T2
T3 (7)
(6)(8)(9) (10)
(10)
(9)
(19)(18)
(22) (12)(12)
(12)
(23)
(12)
(12) (24)
(25) (12)(21)(20)
(1) (2)
(3) (4)(2) (5)
AB
(28)
(29)
(16)
F
F
A
E
T1
T1
DC
D
C
(20)
(12)(12)
(12)
(12)
(12)
(29)
(13) (14)(11) (17)(30)
(27)
(26)
(15)
E
B

FU(H4DOTC)-8
FUEL INJECTION (FUEL SYSTEM)
General Description
(1) Heat shield cover (13) Evaporation hose B (25) Evaporation hose E
(2) Fuel tank band (14) Joint pipe (26) Fuel sub level sensor gasket
(3) Protector LH (15) Evaporation hose C (27) Jet pump filter
(4) Protector RH (16) Evaporation pipe ASSY (28) Fuel sub level sensor
(5) Fuel tank (17) Evaporation pipe (29) Evaporation hose F
(6) Fuel pump gasket (18) Fuel return hose A (30) Evaporation hose G
(7) Fuel pump ASSY (19) Jet pump hose
(8) Fuel level sensor (20) RetainerTightening torque: N
⋅m (kgf-m, ft-lb)
(9) Fuel cut valve gasket (21) Quick connectorT1: 4.4 (0.45, 3.3)
(10) Fuel cut valve (22) Evaporation hose DT2: 7.4 (0.75, 5.4)
(11) Evaporation hose A (23) Fuel pipe ASSYT3: 33 (3.4, 24.3)
(12) Clip (24) Fuel return hose B

FU(H4DOTC)-9
FUEL INJECTION (FUEL SYSTEM)
General Description
5. FUEL LINE
FU-00516
(12)
(11) (1)
(1) (1) (7) (1)(1)(9)(10)
(10)(1)
(6)
(5)
(4)
(3) (2)
(1)(1) (8)
(24)
(24)
(18)
(23)
(13)
(14)
(1)
(1) (21)(20)
(25)
(22)
(19)
(17)
(16)(15)
C
B
B
A
CA
T

FU(H4DOTC)-10
FUEL INJECTION (FUEL SYSTEM)
General Description
(1) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A
(2) Fuel delivery hose A (12) Grommet (22) Connector
(3) Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B
(4) Fuel filter holder (14) Canister (24) Clamp
(5) Fuel filter cup (15) Canister bracket plate (25) Front canister bracket
(6) Fuel filter (16) Cushion
(7) Evaporation hose (17) Canister bracket spacerTightening torque: N
⋅m (kgf-m, ft-lb)
(8) Fuel damper valve (18) Rear canister bracketT: 23 (2.3, 17.0)
(9) Fuel deliver y hose B (19) Two-way valve return hose
(10) Fuel return hose (20) Two-way valve

FU(H4DOTC)-11
FUEL INJECTION (FUEL SYSTEM)
General Description
6. FUEL FILLER PIPE
(1) Fuel filler pipe ASSY (6) Air vent pipe (11) Fuel filler cap tether
(2) Evaporation hose holder (7) Air vent pipe holder (12) Fuel filler pipe protector
(3) Clip (8) Fuel filler pipe packing
(4) Clamp (9) Fuel filler ringTightening torque: N
⋅m (kgf-m, ft-lb)
(5) Air vent hose (10) Fuel filler capT: 7.5 (0.76, 5.5)
FU-00006
(4)
(2)
(8)
(1)
(12)(11)
(6)
(7)
(9)
(10)
(5)
(3)
(3)
T
T
T
T
T

FU(H4DOTC)-12
FUEL INJECTION (FUEL SYSTEM)
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement. Be careful not to burn yourself, because each
part on the vehicle is hot after running.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical system.
22771AA030 SUBARU SELECT
MONITOR KITTroubleshooting for electrical systems.
 English: 22771AA030 (Without printer)
 German: 22771AA070 (Without printer)
 French: 22771AA080 (Without printer)
 Spanish: 22771AA090 (Without printer)
ST24082AA230
ST22771AA030

FU(H4DOTC)-13
FUEL INJECTION (FUEL SYSTEM)
Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intercooler. <Ref. to IN(H4DOTC)-
10, REMOVAL, Intercooler.>
3) Disconnect the connector from the throttle posi-
tion sensor (A) and idle air control solenoid valve
(B) and manifold absolute pressure sensor (C).
4) Disconnect the accelerator cable.
5) Disconnect the engine coolant hoses from throt-
tle body.6) Remove the bolts which secure the throttle body
to intake manifold.B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 16.2 ft-lb)
2) Adjust the accelerator cable play. <Ref. to
SP(H4SO)-9, INSTALLATION, Accelerator Control
Cable.>
FU-00009
(A)(B)
(C)
FU-00010
FU-00011
FU-00012
FU-00013

FU(H4DOTC)-14
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(H4DOTC)-
54, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the ground cable from battery.
4) Lift-up the vehicle.
5) Remove the under cover.
6) Drain the coolant about 3.02 (3.2 US qt, 2.6 Imp
qt).
7) Remove the air cleaner upper cover and air in-
take boot. <Ref. to IN(H4DOTC)-7, REMOVAL, Air
Cleaner.>
8) Remove the air cleaner element.
9) Remove the intercooler. <Ref. to IN(H4DOTC)-
10, REMOVAL, Intercooler.>
10) Disconnect the accelerator cable.
11) Remove the coolant filler tank. <Ref. to
CO(H4SO)-42, REMOVAL, Coolant Filler Tank.>
12) Remove the power steering pump.(1) Remove the front side V-belt. <Ref. to
ME(H4DOTC)-52, REMOVAL, V-belt.>
(2) Disconnect the power steering switch con-
nector.
(3) Remove the bolts which secure the power
steering pipe brackets to intake manifold.
CAUTION:
Do not disconnect the power steering hose.
(4) Remove the bolts which secure the power
steering pump bracket.
(5) Remove the power steering tank from the
bracket by pulling it upward.
FU-00009
FU-00016
FU-00011
FU-00017
FU-00018
FU-00019
FU-00020

FU(H4DOTC)-15
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(6) Place the power steering pump on right side
wheel apron.
13) Disconnect the emission hose from PCV valve.
14) Disconnect the engine coolant hoses from
throttle body.
15) Disconnect the brake booster hose.16) Disconnect the pressure hose from intake duct.
17) Disconnect the engine harness connectors
from bulkhead harness connectors.
18) Disconnect the connectors from the engine
coolant temperature sensor (A), oil pressure switch
(B) and crankshaft position sensor (C).
FU-00021
FU-00022
FU-00012
FU-00023
FU-00024
FU-00025
FU-02086
(A)
(B)
(C)
FU-00027