SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC 2.5)-51
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
15) Connect the battery ground cable to battery.
FU-00009

FU(H4DOTC 2.5)-52
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
24.Fuel Pump
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure.
<Ref. to FU(H4DOTC 2.5)-45, RELEASING OF
FUEL PRESSURE, OPERATION, Fuel.>
2) Open the fuel filler flap lid and remove fuel filler
cap.
3) Disconnect the ground cable from battery.
4) Lift-up the vehicle.
5) Drain fuel from the fuel tank. Set a container un-
der 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)7) Raise the rear seat and turn floor mat up.
8) Remove the access hole lid.
9) Disconnect the connector from fuel pump.
10) Disconnect the quick connector and then dis-
connect fuel delivery hose.
<Ref. to FU(H4DOTC 2.5)-60, Fuel Delivery, Re-
turn and Evaporation Lines.>
11) Move the clips, and then disconnect the fuel re-
turn hose (A) and jet pump hose (B).
12) Remove the nuts which install fuel pump as-
sembly onto fuel tank.
13) Take off the fuel pump assembly from fuel tank.
FU-00009
FU-00089
FU-00089
FU-00105
FU-00106
FU-00376
(B)
(A)
FU-00108

FU(H4DOTC 2.5)-53
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
NOTE:
Replace the gaskets with new ones.
(1) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(2) Tighten the nuts in alphabetical sequence
shown in the figure to specified torque.
Tightening torque:
4.4 N
⋅m (0.45 kgf-m, 3.3 ft-lb)
C: INSPECTION
Connect the lead harness to connector terminal of
fuel pump and apply battery power supply to check
whether the pump operates.
WARNING:
 Wipe off the fuel completely.
 Keep the battery as far apart from fuel pump
as possible.
 Be sure to turn the battery supply ON and
OFF on battery side.
 Do not run the fuel pump for a long time un-
der non-load condition.
FU-00109
(A)
(B)
(C)
(D)
(E)
(F)
(G)(H)
FU-003751 2 3
4 5 6

FU(H4DOTC 2.5)-54
FUEL INJECTION (FUEL SYSTEM)
Fuel Level Sensor
25.Fuel Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly.
<Ref. to FU(H4DOTC 2.5)-52, REMOVAL, Fuel
Pump.>
2) Disconnect the connector from fuel pump brack-
et.
3) Remove the bolt which installs fuel level sensor
on mounting bracket.
B: INSTALLATION
Install in the reverse order of removal.
FU-00111
FU-00112

FU(H4DOTC 2.5)-55
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
26.Fuel Sub Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Drain fuel from the fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
tank.
4) Tighten the fuel drain plug.
Tightening torque:
26 N
⋅m (2.7 kgf-m, 19.2 ft-lb)
5) Remove the rear seat.6) Remove the service hole cover.
7) Disconnect the connector from fuel sub level
sensor.
8) Disconnect the fuel jet pump hose.
9) Remove the bolts which install fuel sub level
sensor on fuel tank.
10) Remove the fuel sub level sensor.
FU-00009
FU-00089
FU-00089
FU-00113
FU-00114
FU-00115
FU-00116

FU(H4DOTC 2.5)-56
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
FU-00115

FU(H4DOTC 2.5)-57
FUEL INJECTION (FUEL SYSTEM)
Fuel Filter
27.Fuel Filter
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Release the fuel pressure.
<Ref. to FU(H4DOTC 2.5)-45, RELEASING OF
FUEL PRESSURE, OPERATION, Fuel.>
2) Disconnect the fuel delivery hoses from fuel filter.
3) Remove the filter from holder.
B: INSTALLATION
CAUTION:
 If fuel hoses are damaged at the connecting
portion, replace it with a new one.
 If clamps are badly damaged, replace with new
ones.
1) Install in the reverse order of removal.
2) Tighten the hose clamp screws.
Tightening torque:
1.25 N·m (0.13 kgf-m, 0.94 ft-lb)
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.
FU-00118
FU-00118

FU(H4DOTC 2.5)-58
FUEL INJECTION (FUEL SYSTEM)
Fuel Cut Valve
28.Fuel Cut Valve
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Remove the fuel tank.
<Ref. to FU(H4DOTC 2.5)-46, REMOVAL, Fuel
Tank.>
2) Move the clip and disconnect the evaporation
hose from fuel cut valve.
3) Remove the bolts which install fuel cut valve.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
FU-00119
FU-00120

FU(H4DOTC 2.5)-59
FUEL INJECTION (FUEL SYSTEM)
Fuel Damper Valve
29.Fuel Damper Valve
A: REMOVAL
1) Release the fuel pressure.
<Ref. to FU(H4DOTC 2.5)-45, RELEASING OF
FUEL PRESSURE, OPERATION, Fuel.>
2) Remove the fuel damper valve from fuel return
line.
B: INSTALLATION
Install in the reverse order of removal.
FU-00121

FU(H4DOTC 2.5)-60
FUEL INJECTION (FUEL SYSTEM)
Fuel Delivery, Return and Evaporation Lines
30.Fuel Delivery, Return and Evaporation Lines
A: REMOVAL
1) Set the vehicle on a lift.
2) Release the fuel pressure. <Ref. to FU(H4DOTC 2.5)-45, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
3) Open the fuel filler flap lid and remove fuel filler cap.
4) Remove the floor mat. <Ref. to EI-49, REMOVAL, Floor Mat.>
5) Remove the fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses.
6) In the engine compartment, detach the fuel de-
livery hoses (A), return hoses (B) and evaporation
hoses (C).
7) Lift-up the vehicle.8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B)
from canister.
FU-00122
(B) (A)
(C)
FU-00374
(A)(B)
FU-00091