SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC)-66
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)-67
FUEL INJECTION (FUEL SYSTEM)
Fuel Filter
30.Fuel Filter
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, 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 connecting por-
tions, replace them with new ones.
 If clamps are badly damaged, replace them
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)-68
FUEL INJECTION (FUEL SYSTEM)
Fuel Cut Valve
31.Fuel Cut Valve
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Remove the fuel tank. 55, REMOVAL, Fuel Tank.>
2) Move the clip and disconnect the evaporation
hose from fuel cut valve.
3) Remove the bolts which install the 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)-69
FUEL INJECTION (FUEL SYSTEM)
Fuel Damper Valve
32.Fuel Damper Valve
A: REMOVAL
1) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
2) Remove the fuel damper valve from fuel return
hose.
B: INSTALLATION
Install in the reverse order of removal.
FU-00121

FU(H4DOTC)-70
FUEL INJECTION (FUEL SYSTEM)
Fuel Delivery, Return and Evaporation Lines
33.Fuel Delivery, Return and Evaporation Lines
A: REMOVAL
1) Set the vehicle on a lift.
2) Release the fuel pressure. Fuel.>
3) Open the fuel filler flap lid and remove the fuel filler cap.
4) Remove the 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

FU(H4DOTC)-71
FUEL INJECTION (FUEL SYSTEM)
Fuel Delivery, Return and Evaporation Lines
9) Separate the quick connector on fuel delivery
line.
(1) Clean the pipe and connector, if they are
covered with dust.
(2) Hold the connector (A) and push retainer (B)
down.
(3) Pull out the connector (A) from retainer (B).
B: INSTALLATION
1) Connect the quick connector on fuel delivery
line.
NOTE:
 Replace the retainer with a new one.
 Make sure the connected portion is not damaged
or has dust. If necessary, clean the seal surface of
pipe.(1) Set the new retainer (B) to connector (A).
(2) Push the pipe into connector completely.
NOTE:
At this time, two clicking sounds are heard.
CAUTION:
 Pull the connector to ensure it is connected
securely.
 Ensure the two retainer pawls are engaged in
their mating positions in connector.
 Be sure to inspect the hoses and their con-
nections for any leakage of fuel.
(A) Connector
(B) Retainer
(C) Pipe
(A) Seal surface
(B) Pipe
FU-00124
(A)(B)
(C)
FU-00125
(A)
(B)
(A) Connector
(B) Retainer
(C) Pipe
(A) Connector
(B) Retainer
(C) Pipe
FU-00126
(C)
(A)
(B)
FU-00127
(A)
(B)
(C)

FU(H4DOTC)-72
FUEL INJECTION (FUEL SYSTEM)
Fuel Delivery, Return and Evaporation Lines
2) Connect the fuel delivery hose to pipe with an
overlapof 20 to 25 mm (0.79 to 0.98 in).
Type A: When the fitting length is specified.
Type B: When the fitting length is not specified.
2: 2.5
±1.5 mm (0.098±0.059 in)
L: 22.5
±2.5 mm (0.886±0.098 in)
3) Connect the evaporation hose to pipe by approx.
15 — 20 mm (0.59 — 0.79 in) from hose end.
L = 17.5
±2.5 mm (0.689±0.098 in)
CAUTION:
Be sure to inspect the hoses and their connec-
tions for any leakage of fuel.
C: INSPECTION
1) Make sure there are no cracks on fuel pipes and
fuel hoses.
2) Make sure the fuel pipe and fuel hose connec-
tions are tightened firmly.
(1) Fitting
(2) Clamp
(3) Hose
(1) Hose
(2) Clip
(3) Pipe
FU-00128
(1) (2)(3)
L
Type A
Type B
FU-00129
(1)(2)
L/2
L(3)

FU(H4DOTC)-73
FUEL INJECTION (FUEL SYSTEM)
Fuel System Trouble in General
34.Fuel System Trouble in General
A: INSPECTION
NOTE:
 When the vehicle is left unattended for an ex-
tended period of time, water may accumulate in the
fuel tank.
To prevent water condensation.
(1) Top off the fuel tank or drain the fuel com-
pletely.
(2) Drain the water condensation from the fuel
filter.
 Refilling the fuel tank.
Refill the fuel tank while there is still some fuel left in
the tank.
 Protecting the fuel system against freezing and
water condensation.
Cold areas
In snow-covered areas, mountainous areas, skiing
areas, etc. where ambient temperatures drop be-
low 0°C (32°F) throughout the winter season, use
an anti-freeze solution in the fuel tank. Refueling
will also complement the effect of anti-freeze solu-
tion each time the fuel level drops to about one-half. After the winter season, drain the water which
may have accumulated in the fuel filter and fuel
tank in the manner same as that described under
Affected areas below.
 Affected areas
When the water condensation is notched in the fuel
filter, drain the water from both the fuel filter and
fuel tank or use a water removing agent (or anti-
freeze solution) in the fuel tank.
 Observe the instructions, notes, etc., indicated
on the label affixed to the anti-freeze solution (wa-
ter removing agent) container before use.
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
❍Defective terminal contact.Inspect connections, especially ground, and tighten
securely.
❍Trouble in electromagnetic or electronic circuit parts. Replace fuel pump.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
5) Clogged or bent air breather tube or air vent tube.Clean, correct or replace air breather tube or air vent
tube.
3. Gasoline smell inside of compartment
1)Loose joints at air breather tube, air vent tube and fuel filler
pipe.Retightening.
2) Defective packing air tightness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.

FU(H4DOTC)-74
FUEL INJECTION (FUEL SYSTEM)
Fuel System Trouble in General

FUJI HEAVY INDUSTRIES LTD. G8080GE3
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 2
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.FUEL INJECTION (FUEL SYSTEM) FU(H4DOTC)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC)
INTAKE (INDUCTION) IN(H4DOTC)
MECHANICAL ME(H4DOTC)
EXHAUST EX(H4DOTC)
COOLING CO(H4DOTC)
LUBRICATION LU(H4DOTC)
SPEED CONTROL SYSTEM SP(H4DOTC)
IGNITION IG(H4DOTC)
STARTING/CHARGING SYSTEM SC(H4DOTC)
ENGINE (DIAGNOSTIC) EN(H4DOTC)