SUBARU FORESTER 2004 Service Repair Manual

FUEL INJECTION (FUEL SYSTEM)
FU(H4DOTC 2.5)
Page
1. General Description ....................................................................................2
2. Throttle Body .............................................................................................13
3. Intake Manifold ..........................................................................................14
4. Engine Coolant Temperature Sensor........................................................26
5. Crankshaft Position Sensor.......................................................................27
6. Camshaft Position Sensor.........................................................................28
7. Knock Sensor ............................................................................................29
8. Mass Air Flow and Intake Air Temperature Sensor ..................................30
9. Manifold Absolute Pressure Sensor ..........................................................31
10. Fuel Injector ..............................................................................................32
11. Tumble Generator Valve Assembly ..........................................................33
12. Tumble Generator Valve Actuator.............................................................34
13. Wastegate Control Solenoid Valve ...........................................................35
14. Front Oxygen (A/F) Sensor .......................................................................36
15. Rear Oxygen Sensor.................................................................................38
16. Exhaust Temperature Sensor ...................................................................40
17. Engine Control Module (ECM) ..................................................................41
18. Main Relay ................................................................................................42
19. Fuel Pump Relay.......................................................................................43
20. Fuel Pump Control Unit .............................................................................44
21. Fuel ...........................................................................................................45
22. Fuel Tank ..................................................................................................46
23. Fuel Filler Pipe ..........................................................................................48
24. Fuel Pump .................................................................................................52
25. Fuel Level Sensor .....................................................................................54
26. Fuel Sub Level Sensor ..............................................................................55
27. Fuel Filter ..................................................................................................57
28. Fuel Cut Valve...........................................................................................58
29. Fuel Damper Valve ...................................................................................59
30. Fuel Delivery, Return and Evaporation Lines............................................60
31. Fuel System Trouble in General ...............................................................63

FU(H4DOTC 2.5)-2
FUEL INJECTION (FUEL SYSTEM)
General Description
1. General Description
A: SPECIFICATION
Fuel tankCapacity 602 (15.9 US gal, 13.2 Imp gal)
Location Under rear seat
Fuel pumpType Impeller
Shutoff discharge pressure
450 — 677 kPa (4.59 — 6.9 kg/cm
2, 65.27 — 98.2 psi)
Discharge flowMore than 1302 (34.3 US gal, 28.6 Imp gal)/h
[12 V at 300 kPa (3.06 kg/cm
2, 43.5 psi)]
Fuel filterCartridge type

FU(H4DOTC 2.5)-3
FUEL INJECTION (FUEL SYSTEM)
General Description
B: COMPONENT
1. INTAKE MANIFOLD
FU-02105
(14)
T4
T4
T4
T1 (22) (22)
(21)
(6)
(2)
(3)
T5
(1)
(5)
(3) (2)(4)
(11)
(12) (13)
(20)
T1
T1
T3
T2
T4
T4
T4
T2
T5
T4
T4
(8)
(7)
(17)
(19)(16)
(18)
(7)
(10)
(10)
(11)
(13)
(8)
(9)
(23)(23)
T2
(9)
(12)
T4
(15)
T4

FU(H4DOTC 2.5)-4
FUEL INJECTION (FUEL SYSTEM)
General Description
(1) Fuel pipe ASSY (12) O-ring (22) Purge hose
(2) Fuel hose (13) Fuel injector pipe (23) Tumble generator valve actuator
(3) Clamp (14) Pressure regulator
(4) Purge control solenoid valve (15) Pressure regulator hoseTightening torque: N·m (kgf-m, ft-lb)
(5) Vacuum hose (16) Fuel pipe protector RHT1: 5 (0.5, 3.7)
(6) Vacuum control hose (17) Blow-by hose stayT2: 8.25 (0.84, 6.1)
(7) Intake manifold gasket (18) Intake manifoldT3: 17 (1.73, 12.5)
(8) Guide pin (19) Wastegate control solenoid valve
ASSYT4: 19 (1.94, 13.7)
(9) Tumble generator valve ASSYT5: 25 (2.5, 18.1)
(10) Tumble generator valve gasket (20) Nipple
(11) Fuel injector (21) Purge valve

FU(H4DOTC 2.5)-5
FUEL INJECTION (FUEL SYSTEM)
General Description
2. AIR INTAKE SYSTEM
(1) Gasket (3) Manifold absolute pressure sensorTightening torque: N·m (kgf-m, ft-lb)
(2) Throttle body (4) O-ringT1: 1.6 (0.16, 1.2)
T2: 8 (0.8, 5.8)
FU-01072
T1T2
(1)(3)
(2)
(4)

FU(H4DOTC 2.5)-6
FUEL INJECTION (FUEL SYSTEM)
General Description
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
(1) Crankshaft position sensor (3) Camshaft position sensor LHTightening torque: N·m (kgf-m, ft-lb)
(2) Knock sensor (4) Camshaft position sensor RHT1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU-01036
T1
(4)
T1
T2
T1
(3)
(2) (1)

FU(H4DOTC 2.5)-7
FUEL INJECTION (FUEL SYSTEM)
General Description
4. FUEL TANK
FU-00909
T1
T1
T3
T2
T2
T2
T2
T3 (7)
(6)(8)(9) (10)
(10)
(9)
(19)(18)
(22) (12)(12)
(12)
(23)
(12)
(12) (24)
(25) (12)(21)(20)
(1) (2)
(3) (4)(2) (5)
AB
(28)
(29)
(16)
F
F
A
E
T1
T1
DC
D
C
(20)
(12)(12)
(12)
(12)
(12)
(29)
(13) (14)(11) (17)(30)
(27)
(26)
(15)
E
B

FU(H4DOTC 2.5)-8
FUEL INJECTION (FUEL SYSTEM)
General Description
(1) Heat shield cover (13) Evaporation hose B (25) Evaporation hose E
(2) Fuel tank band (14) Joint pipe (26) Fuel sub level sensor gasket
(3) Protector LH (15) Evaporation hose C (27) Jet pump filter
(4) Protector RH (16) Evaporation pipe ASSY (28) Fuel sub level sensor
(5) Fuel tank (17) Evaporation pipe (29) Evaporation hose F
(6) Fuel pump gasket (18) Fuel return hose A (30) Evaporation hose G
(7) Fuel pump ASSY (19) Jet pump hose
(8) Fuel level sensor (20) RetainerTightening torque: N·m (kgf-m, ft-lb)
(9) Fuel cut valve gasket (21) Quick connectorT1: 4.4 (0.45, 3.3)
(10) Fuel cut valve (22) Evaporation hose DT2: 7.4 (0.75, 5.4)
(11) Evaporation hose A (23) Fuel pipe ASSYT3: 33 (3.4, 24.3)
(12) Clip (24) Fuel return hose B

FU(H4DOTC 2.5)-9
FUEL INJECTION (FUEL SYSTEM)
General Description
5. FUEL LINE
FU-00516
(12)
(11) (1)
(1) (1) (7) (1)(1)(9)(10)
(10)(1)
(6)
(5)
(4)
(3) (2)
(1)(1) (8)
(24)
(24)
(18)
(23)
(13)
(14)
(1)
(1) (21)(20)
(25)
(22)
(19)
(17)
(16)(15)
C
B
B
A
CA
T

FU(H4DOTC 2.5)-10
FUEL INJECTION (FUEL SYSTEM)
General Description
(1) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A
(2) Fuel delivery hose A (12) Grommet (22) Connector
(3) Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B
(4) Fuel filter holder (14) Canister (24) Clamp
(5) Fuel filter cup (15) Canister bracket plate (25) Front canister bracket
(6) Fuel filter (16) Cushion
(7) Evaporation hose (17) Canister bracket spacerTightening torque: N·m (kgf-m, ft-lb)
(8) Fuel damper (18) Rear canister bracketT: 23 (2.3, 17.0)
(9) Fuel deliver y hose B (19) Two-way valve return hose
(10) Fuel return hose (20) Two-way valve