warning SUBARU FORESTER 2004 Service Owners Manual

FU(H4SO)-49
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
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. INSTALLATION, Fuel Delivery, Return and Evapo-
ration 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. 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.
FU-00411
(A)(B)
FU-00091
FU-00092
FU-00093
FU-00411
(B)
(A)
FU-00090

FU(H4SO)-51
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
21.Fuel Filler Pipe
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Set the vehicle on a lift.
2) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, 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(H4SO)-55
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
22.Fuel Pump
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, 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. REMOVAL, Fuel Delivery, Return and Evaporation
Lines.>
FU-00009
FU-00089
FU-00089
FU-00105
FU-00106

FU(H4SO)-56
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
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.
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
NOTE:
Always use new gaskets.
(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-00107
(B)(A)
FU-00108
FU-00109
(A)
(B)
(C)
(D)
(E)
(F)
(G)(H)FU-00110
1 2 3
4 5 6

FU(H4SO)-57
FUEL INJECTION (FUEL SYSTEM)
Fuel Level Sensor
23.Fuel Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. FU(H4SO)-55, 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(H4SO)-58
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
24.Fuel Sub Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
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(H4SO)-60
FUEL INJECTION (FUEL SYSTEM)
Fuel Filter
25.Fuel Filter
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Disconnect the fuel delivery hoses from fuel fil-
ter.
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(H4SO)-61
FUEL INJECTION (FUEL SYSTEM)
Fuel Cut Valve
26.Fuel Cut Valve
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Remove the fuel tank. 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

ME(H4SO)-29
MECHANICAL
Engine Oil Pressure
6. Engine Oil Pressure
A: INSPECTION
1) Disconnect the ground cable from battery.
2) Remove the generator from bracket. SC(H4SO)-15, REMOVAL, Generator.>
3) Disconnect the connector from oil pressure
switch.
4) Remove the oil pressure switch from cylinder
block. sure Switch.>
5) Connect the oil pressure gauge hose to cylinder
block.
6) Connect the battery ground cable to battery.
7) Start the engine, and then measure the oil pres-
sure.
Oil pressure:
Standard:
88 kPa (0.9 kg/cm
2, 13 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpmCAUTION:
 If the oil pressure is out of specification,
check the oil pump, oil filter and lubrication
line. gine Lubrication System Trouble in General.>
 If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. SPECTION, Engine Lubrication System Trouble
in General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
8) After measuring the oil pressure, install the oil
pressure switch. LATION, Oil Pressure Switch.>
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
9) Install the generator and V-belt in the reverse or-
der of removal, and then adjust the V-belt deflec-
tion. belt.>
FU-00009
FU-00009
ME-00196

ME(H4SO)-30
MECHANICAL
Fuel Pressure
7. Fuel Pressure
A: INSPECTION
WARNING:
Before removing the fuel pressure gauge, re-
lease the fuel pressure.
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
1) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel flap lid, and then remove the fuel
filler cap.
3) Disconnect the fuel delivery hoses from fuel
damper, and then connect the fuel pressure gauge.
4) Connect the connector of fuel pump relay.
5) Start the engine.
6) Measure the fuel pressure while disconnecting
the pressure regulator vacuum hose from intake
manifold.Fuel pressure:
Standard:
284 — 314 kPa (2.9 — 3.2 kg/cm
2, 41 — 46 psi)
7) After connecting the pressure regulator vacuum
hose, measure the fuel pressure.
Fuel pressure:
Standard:
206 — 235 kPa (2.1 — 2.4 kg/cm
2, 30 — 34 psi)
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kg/cm
2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
FU-00208
FU-00262
ME-00198
ME-00198