SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC)-46
FUEL INJECTION (FUEL SYSTEM)
Front Oxygen (A/F) Sensor
3) Install the service hole cover.
4) Lower the vehicle.
5) Install the front right side wheel.
6) Connect the engine harness with clip (A) to
bracket (B).
7) Connect the connector of front oxygen (A/F)
sensor.
8) Connect the battery ground cable to battery.
FU-00079
FU-00078
(A)(B)
FU-02088
FU-00009

FU(H4DOTC)-47
FUEL INJECTION (FUEL SYSTEM)
Rear Oxygen Sensor
18.Rear Oxygen Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Disconnect the connector from rear oxygen sen-
sor.
4) Remove the clip by pulling it out from the upper
side of crossmember.
 AT model
 MT model5) Apply SUBARU CRC or its equivalent to the
threaded portion of rear oxygen sensor, and leave
it for 1 minute or more.
SUBARU CRC (Part No. 004301003)
6) Remove the rear oxygen sensor.
CAUTION:
When removing the oxygen sensor, wait until
the exhaust pipe cools, otherwise it will dam-
age the exhaust pipe.
B: INSTALLATION
1) Before installing the rear oxygen sensor, apply
anti-seize compound only to the threaded portion of
rear oxygen sensor to make next removal easier.
CAUTION:
Never apply anti-seize compound to the protec-
tor of rear oxygen sensor.
Anti-seize compound:
SS-30 JET LUBE
2) Install the rear oxygen sensor.
Tightening torque:
21 N
⋅m (2.1 kgf-m, 15.2 ft-lb)
FU-00009
FU-00081
FU-01311
FU-01312
FU-00371
FU-00371

FU(H4DOTC)-48
FUEL INJECTION (FUEL SYSTEM)
Rear Oxygen Sensor
3) Connect the connector to rear oxygen sensor.
4) Connect the clip to crossmember.
 AT model
 MT model
5) Lower the vehicle.
6) Connect the battery ground cable to battery.
FU-00081
FU-01311
FU-01312
FU-00009

FU(H4DOTC)-49
FUEL INJECTION (FUEL SYSTEM)
Exhaust Temperature Sensor
19.Exhaust Temperature Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the joint pipe. 13, REMOVAL, Joint Pipe.>
3) Apply SUBARU CRC or its equivalent to the
threaded portion of exhaust temperature sensor,
and leave it for 1 minute or more.
SUBARU CRC (Part No. 004301003)
4) Remove the exhaust temperature sensor.
CAUTION:
When removing the exhaust temperature sen-
sor, wait until the exhaust pipe cools, otherwise
it will damage the exhaust pipe.
B: INSTALLATION
1) Before installing the exhaust temperature sen-
sor, apply anti-seize compound only to the thread-
ed portion of the exhaust temperature sensor to
make next removal easier.
CAUTION:
Never apply anti-seize compound to the protec-
tor of exhaust temperature sensor.
Anti-seize compound:
SS-30 JET LUBE
2) Install the exhaust temperature sensor.
NOTE:
Align the harness (A) direction of exhaust tempera-
ture sensor to the marking (B) of joint pipe, and
tighten the screws.
Tightening torque:
21 N
⋅m (2.1 kgf-m, 15.2 ft-lb)
3) Install the joint pipe. INSTALLATION, Joint Pipe.>
4) Connect the battery ground cable to battery.
FU-00009
FU-00372
FU-01018
(A)
(B)
FU-00009

FU(H4DOTC)-50
FUEL INJECTION (FUEL SYSTEM)
Engine Control Module (ECM)
20.Engine Control Module (ECM)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the lower inner trim of passenger side.

3) Detach the floor mat of front passenger seat
side.
4) Remove the protect cover.
5) Remove the nuts (A) which hold the ECM to
bracket.
6) Remove the clip (B) from bracket.
7) Disconnect the ECM connectors and take out
the ECM.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
When replacing the ECM, be careful not to use the
wrong spec. ECM to avoid any damage to the fuel
injection system.
FU-00009
FU-00084
(A)
(A)
(B)
FU-00085

FU(H4DOTC)-51
FUEL INJECTION (FUEL SYSTEM)
Main Relay
21.Main Relay
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the glove box. AL, Glove Box.>
3) Remove the bolt which holds the main relay
bracket on body.
4) Disconnect the connectors from main relay.
B: INSTALLATION
Install in the reverse order of removal.
FU-00009
FU-00317

FU(H4DOTC)-52
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump Relay
22.Fuel Pump Relay
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the glove box. AL, Glove Box.>
3) Remove the bolt which holds the fuel pump relay
bracket on body.
4) Disconnect the connector from fuel pump relay.
5) Remove the fuel pump relay from mounting
bracket.
B: INSTALLATION
Install in the reverse order of removal.
FU-00009
FU-00262

FU(H4DOTC)-53
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump Control Unit
23.Fuel Pump Control Unit
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the rear quarter trim. REMOVAL, Rear Quarter Trim.>
3) Disconnect the connector from fuel pump control
unit.
4) Remove the fuel pump control unit.
B: INSTALLATION
Install in the reverse order of removal.
FU-00009
FU-00087
FU-00088

FU(H4DOTC)-54
FUEL INJECTION (FUEL SYSTEM)
Fuel
24.Fuel
A: OPERATION
1. RELEASING OF FUEL PRESSURE
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Disconnect the connector from fuel pump relay.
2) Start and run the engine until it stalls.
3) After the engine stalls, crank it for 5 more sec-
onds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Open the fuel filler flap lid and remove the fuel
filler cap.
4) Lift-up the vehicle.5) Drain fuel from the fuel tank.
Set a container under 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)-55
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
25.Fuel Tank
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Set the vehicle on a lift.
2) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
3) Drain fuel from fuel tank. 54, 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 the fuel tank
cord on floor panel down under body.
7) Remove the rear crossmember. 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 the quick con-
nector. Delivery, Return and Evaporation Lines.>
11) Disconnect the fuel hoses.
12) Support the fuel tank with transmission jack, re-
move the bolts from bands, and then dismount the
fuel tank from vehicle.
WARNING:
A helper is required to perform this work.
(B)
(A)
FU-00090
(A)
(B)
FU-00091
FU-00092
FU-00093
FU-00411