SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC)-16
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
19) Disconnect the knock sensor connector.
20) Disconnect the connector from crankshaft posi-
tion sensor.
21) Disconnect the connector from camshaft posi-
tion sensor.
22) Disconnect the connector from AVCS camshaft
position sensor.23) Disconnect the connector from oil flow control
solenoid valve.
24) Disconnect the connector from ignition coil.
25) Disconnect the engine harness fixed by clip (A)
from bracket.
FU-00028
FU-00029
FU-00059
FU-00061
ME-00711
FU-00030
FU-00031
(A)

FU(H4DOTC)-17
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
26) Disconnect the fuel delivery hose, return hose
and evaporation hose.
CAUTION:
 Do not spill fuel.
 Catch the fuel from hoses in a container or
cloth.
27) Remove the bolts which secure the intake man-
ifold to cylinder heads.
28) Disconnect the ground cable connector.
29) Remove the intake manifold.B: INSTALLATION
1) Install the intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.4 ft-lb)
2) Connect the ground cable.
3) Connect the fuel delivery hose, return hose and
evaporation hose.
FU-00032
FU-00033
FU-00131
FU-00132
FU-00033
FU-00131
FU-00132
FU-00032

FU(H4DOTC)-18
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
4) Connect the connector to the oil pressure switch
(B), crankshaft position sensor (C) and engine
coolant temperature sensor (A).
5) Connect the connector to knock sensor.
6) Connect the connector to crankshaft position
sensor.
7) Connect the connector to camshaft position sen-
sor.8) Connect the connector to AVCS camshaft posi-
tion sensor.
9) Connect the connector to oil flow control sole-
noid valve.
10) Connect the connector to ignition coil.
11) Connect the engine harness with clip (A) to the
bracket.
(A)
(B)
(C)
FU-00027
FU-00028
FU-00029
FU-00059
FU-00061
ME-00711
FU-00030
FU-00031
(A)

FU(H4DOTC)-19
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
12) Connect the engine harness connector to bulk-
head harness connectors.
13) Connect the brake booster vacuum hose.
14) Connect the engine coolant hoses to throttle
body.15) Connect the emission hose to PCV valve.
16) Connect the pressure hose to intake duct.
17) Install the power steering pump.
(1) Install the power steering tank on bracket.
(2) Connect the connector to the power steering
pump switch.
FU-00025
FU-02086
FU-00023
FU-00012
FU-00022
FU-00024
FU-00020
FU-00017

FU(H4DOTC)-20
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(3) Install the power steering pump, and then
tighten the bolts.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 16.2 ft-lb)
(4) Install the power steering pipe brackets on
right side intake manifold.
(5) Install the front side V-belt. ME(H4DOTC)-52, REMOVAL, V-belt.>
18) Install the coolant filler tank. 42, INSTALLATION, Coolant Filler Tank.>
19) Connect the accelerator cable. SP(H4SO)-9, INSTALLATION, Accelerator Control
Cable.>
20) Install the intercooler. 11, INSTALLATION, Intercooler.>
21) Install the air cleaner element.
22) Install the air cleaner upper cover and air intake
duct as a unit. TION, Air Cleaner.>23) Connect the connector to the fuel pump relay.
24) Connect the battery ground cable to battery.
25) Lift-up the vehicle.
26) Install the under cover.
27) Fill the coolant. ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
FU-00019
FU-00018
FU-00011
FU-00262
FU-00009

FU(H4DOTC)-21
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
C: DISASSEMBLY
1) Remove the fuel pipe protector LH.
NOTE:
Bolt (A) is tightened together with ground cable.
2) Remove the fuel pipe protector RH.
NOTE:
Bolt (A) is tightened together with ground cable.
3) Remove the engine ground cable from intake
manifold.4) Disconnect the connector from the throttle posi-
tion sensor (A), idle air control solenoid valve (B)
and manifold absolute pressure sensor (C).
5) Disconnect the engine harness fixed by clip (D)
from intake manifold.
6) Remove the throttle body from intake manifold.
7) Disconnect the connector from fuel injector.
8) Disconnect the connector from tumble generator
valve actuator.
(A)
FU-00523
FU-00522
(A)
FU-00036
FU-00037
FU-00038
(A)
(B) (C)
(D) (D)
FU-00013
FU-00615
FU-00616

FU(H4DOTC)-22
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
9) Disconnect the connector from tumble generator
valve sensor.
10) Disconnect the connector from purge control
solenoid valve.
11) Remove the purge control solenoid valve.
12) Disconnect the evaporation hose from intake
manifold.13) Disconnect the evaporation hose from purge
valve.
14) Remove the two bolts which hold the fuel pipes
on the left side of intake manifold.
15) Remove the bolts which hold the fuel injector
pipe onto intake manifold.
 LH SIDE
FU-00617
FU-00040
FU-00041
FU-00042
FU-00364
FU-00043
FU-00044
FU-00618

FU(H4DOTC)-23
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
 RH SIDE
16) Remove the fuel injector.
17) Remove the harness bracket which holds the
engine harness onto intake manifold.
18) Remove the engine harness from intake mani-
fold.19) Loosen the clamp which holds the front left side
fuel hose to injector pipe, and remove the pipe from
clamp.
20) Remove the fuel injector pipe LH.
21) Remove the bolts which install the fuel pipe on
intake manifold.
22) Remove the fuel pipe assembly and pressure
regulator from intake manifold.
23) Remove the intake duct from intake manifold.
24) Remove the intake manifold.
FU-00046
FU-00619
FU-00048
FU-00049
FU-00620
FU-00051
IN-00250
FU-00053

FU(H4DOTC)-24
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
D: ASSEMBLY
NOTE:
Replace the gasket with a new one.
1) Install the intake manifold.
Tightening torque:
8.25 N
⋅m (0.84 kgf-m, 6.1 ft-lb)
2) Install the air intake duct to intake manifold.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
3) Install the fuel pipe assembly and pressure reg-
ulator to intake manifold.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.7 ft-lb)
4) Install the fuel injector pipe LH.5) Connect the left side fuel hose to injector pipe,
and tighten the clamp screw.
6) Install the engine harness to intake manifold.
7) Install the harness bracket which holds the en-
gine harness onto intake manifold.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
8) Install the fuel injector.FU-00053
IN-00250
FU-00051
FU-00620
FU-00049
FU-00048

FU(H4DOTC)-25
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
9) Tighten the bolts which install the fuel injector
pipe onto intake manifold.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
 LH SIDE
 RH SIDE10) Tighten the two bolts which install the fuel pipe
assembly on the left side of intake manifold.
Tightening torque:
5 N⋅m (0.5 kgf-m, 3.7 ft-lb)
11) Connect the evaporation hoses to the purge
valve. (Except Australia model)
NOTE:
Connect the evaporation hose as shown in the fig-
ure.
FU-00044
FU-00618
FU-00046
FU-00619
(A) To fuel pipe ASSY
(B) To intake duct
(C) To purge control solenoid valve
(D) To intake manifold
FU-00043
FU-00365
(A)(B)
(C)
(D)