SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC 2.5)-41
FUEL INJECTION (FUEL SYSTEM)
Engine Control Module (ECM)
17.Engine Control Module (ECM)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the lower inner trim of the passenger
side. <Ref. to EI-44, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of the front passenger seat.
4) Remove the protect cover.
5) Remove the nuts (A) which hold ECM to the
bracket.
6) Remove the clip (B) from the bracket.
7) Disconnect the ECM connectors and take out
the ECM.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
When replacing ECM, be careful not to use the
wrong spec. ECM to avoid any damage to the fuel
injection system.
FU-00009
FU-01029
(A)
(A)
(B)
FU-00316

FU(H4DOTC 2.5)-42
FUEL INJECTION (FUEL SYSTEM)
Main Relay
18.Main Relay
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the glove box. <Ref. to EI-37, REMOV-
AL, Glove Box.>
3) Remove the bolt which holds the main relay
bracket on the body.
4) Disconnect the connectors from the main relay.
B: INSTALLATION
Install in the reverse order of removal.
FU-00009
FU-00317

FU(H4DOTC 2.5)-43
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump Relay
19.Fuel Pump Relay
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the glove box. <Ref. to EI-37, REMOV-
AL, Glove Box.>
3) Remove the bolt which holds fuel pump relay
bracket on the body.
4) Disconnect the connector from the fuel pump re-
lay.
5) Remove the fuel pump relay from the mounting
bracket.
B: INSTALLATION
Install in the reverse order of removal.
FU-00009
FU-00262

FU(H4DOTC 2.5)-44
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump Control Unit
20.Fuel Pump Control Unit
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the rear quarter trim. <Ref. to EI-45, RE-
MOVAL, Rear Quarter Trim.>
3) Disconnect the connector from the fuel pump con-
trol unit.
4) Remove the fuel pump control unit.
B: INSTALLATION
Install in the reverse order of removal.
FU-00009
FU-00088

FU(H4DOTC 2.5)-45
FUEL INJECTION (FUEL SYSTEM)
Fuel
21.Fuel
A: OPERATION
1. RELEASING OF FUEL PRESSURE
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Disconnect the connector from fuel pump relay.
2) Start the engine and run it until it stalls.
3) After the engine stalls, crank it for 5 more seconds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Open the fuel filler flap lid and remove fuel filler
cap.
4) Lift-up the vehicle.5) Drain fuel from the fuel tank.
Set a container under the vehicle and remove the
drain plug from fuel tank.
6) Tighten the fuel drain plug.
Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
FU-00262
FU-00009
FU-00089
FU-00089

FU(H4DOTC 2.5)-46
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
22.Fuel Tank
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Set the vehicle on a lift.
2) Release the fuel pressure.
<Ref. to FU(H4DOTC 2.5)-45, RELEASING OF
FUEL PRESSURE, OPERATION, Fuel.>
3) Drain fuel from the fuel tank.
<Ref. to FU(H4DOTC 2.5)-45, DRAINING FUEL,
OPERATION, Fuel.>
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to
rear harness.
6) Push the grommet (B) which holds fuel tank cord
on floor panel into under the body.
7) Remove the rear crossmember. <Ref. to RS-18,
REMOVAL, Rear Crossmember.>
8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B)
from canister.9) Loosen the clamp and disconnect the fuel filler
hose and air vent hose from fuel filler pipe.
10) Move the clips, and disconnect quick connec-
tor. <Ref. to FU(H4DOTC 2.5)-60, REMOVAL, Fuel
Delivery, Return and Evaporation Lines.>
11) Disconnect the fuel hoses.
12) Support the fuel tank with transmission jack,
and remove the bolts from bands and dismount fuel
tank from the vehicle.
WARNING:
A helper is required to perform this work.
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
(B)
(A)
FU-00090
(A)
(B)
FU-00091
FU-00092
FU-00093
FU-00411

FU(H4DOTC 2.5)-47
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
WARNING:
A helper is required to perform this work.
3) Connect the two-way valve hose (A) to two-way
valve and connect the canister hose (B) to canister.
4) Connect the fuel filler hose and air vent hose.
5) Connect the fuel hoses, and secure them with
clips and quick connector.
<Ref. to FU(H4DOTC 2.5)-61, INSTALLATION,
Fuel Delivery, Return and Evaporation Lines.>6) Tighten the band mounting bolts.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
7) Install the rear crossmember. <Ref. to RS-18,
INSTALLATION, Rear Crossmember.>
8) Connect the connector (A) to fuel tank cord and
plug the service hole with grommet (B).
9) Set the rear seat and floor mat.
10) Connect the connector to fuel pump relay.
C: INSPECTION
1) Make sure there are no cracks, holes, or other
damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and that connections are tight.
FU-00411
(A)(B)
FU-00091
FU-00092
FU-00093
FU-00411
(B)
(A)
FU-00090
FU-00262

FU(H4DOTC 2.5)-48
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
23.Fuel Filler Pipe
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Set the vehicle on a lift.
2) Release the fuel pressure.
<Ref. to FU(H4DOTC 2.5)-45, RELEASING OF
FUEL PRESSURE, OPERATION, Fuel.>
3) Open the fuel filler flap lid and remove fuel filler
cap.
4) Disconnect the ground cable from battery.
5) Remove the screws holding packing in place.
6) Loosen the rear right side wheel nuts.
7) Lift-up the vehicle.
8) Remove the rear right side wheel.9) Drain fuel from the fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
tank.
10) Tighten the fuel drain plug and then install the
front right side tank cover.
Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
11) Remove the fuel filler pipe protector.
12) Separate the evaporation hoses from clip of
fuel filler pipe.
FU-00009
FU-00095
FU-00096
FU-00089
FU-00089
FU-00097
FU-00098

FU(H4DOTC 2.5)-49
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
13) Disconnect the air vent hose from fuel filler
pipe.
14) Remove the bolts which hold fuel filler pipe
bracket on body.
15) Loosen the clamp and separate fuel filler hose
(A) from fuel filler pipe.
16) Move the clip and separate air vent hose (B).
17) Remove the fuel filler pipe to under side of the
vehicle.
18) Remove the air vent pipe together with clip
from body.B: INSTALLATION
1) Hold the fuel filler flap open.
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set cup
(B), and tighten the screws.
NOTE:
If the edges of rubber packing are folded toward in-
side, straighten it with a screwdriver.
4) Install the air vent pipe.
5) Connect the air vent hose to fuel filler pipe.
FU-00099
FU-00100
(A)
(B)
FU-00101
FU-00102
FU-00103
(A)
(C)
(B)
FU-00102
FU-00099

FU(H4DOTC 2.5)-50
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
6) Insert the fuel filler hose (A) approx. 35 to 40 mm
(1.38 to 1.57 in) over the lower end of fuel filler pipe
and tighten the clamp.
CAUTION:
Do not allow clips to touch the air vent hose (B)
and rear suspension crossmember.
7) Insert the air vent hose approx. 25 to 30 mm
(0.98 to 1.18 in) into the lower end of air vent pipe
and hold clip.
L = 27.5
±2.5 mm (1.083±0.098 in)
8) Tighten the bolt which holds fuel filler pipe brack-
et on body.
Tightening torque:
7.5 N·m (0.75 kgf-m, 5.4 ft-lb)9) Hold the evaporation hoses onto clip of fuel filler
pipe.
10) Install the fuel filler pipe protector.
11) Install the rear right wheel.
12) Lower the vehicle.
13) Tighten the wheel nuts.
14) Connect the connector to fuel pump relay.
(1) Hose
(2) Clip
(3) Pipe
(A)
(B)
FU-00101
FU-00104
(1)(2)
L/2
L(3)
FU-00100
FU-00098
FU-00097
FU-00096
FU-00262