SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC 2.5)-21
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
12) Remove the bolt which hold the fuel injector
pipe onto intake manifold.
 LH SIDE
 RH SIDE13) Remove the harness bracket which holds the
engine harness onto intake manifold.
14) Remove the engine harness from the intake
manifold.
15) Loosen the clamp which holds the front left side
fuel hose to injector pipe, and then remove the pipe
from clamp.
16) Loosen the clamp which holds the right side
fuel hose to injector pipe, and then remove the pipe
from clamp.
17) Remove the bolts which install the fuel pipe on
intake manifold.
FU-01046
FU-01047
FU-01048
FU-01049
FU-00049
FU-01050
FU-01051
FU-01052

FU(H4DOTC 2.5)-22
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
18) Remove the fuel pipe assembly and pressure
regulator from the intake manifold.
19) Remove the intake duct from the intake manifold.
20) Remove the tumble generator valve assembly
from the intake manifold.
D: ASSEMBLY
NOTE:
Replace the gasket with a new one.
1) Install the tumble generator valve assembly to
the intake manifold.
Tightening torque:
8.25 N·m (0.84 kgf-m, 6.1 ft-lb)2) Install the air intake duct to the intake manifold.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
3) Install the fuel pipe assembly and pressure reg-
ulator to the intake manifold.
Tightening torque:
T1: 5 N·m (0.5 kgf-m, 3.7 ft-lb)
T2: 19 N·m (1.94 kgf-m, 13.7 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 fuel injector pipe RH.
FU-01076
FU-00053
FU-00053
FU-01076
FU-02104
T1
T2
FU-01050

FU(H4DOTC 2.5)-23
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
7) Connect the right side fuel hose to injector pipe,
and tighten the clamp screw.
8) Install the engine harness to the intake manifold.
9) Install the harness bracket which holds the en-
gine harness onto intake manifold.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)10) Tighten the bolts which install the fuel injector
pipe onto intake manifold.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
 LH SIDE
 RH SIDE
FU-01051
FU-00049
FU-01046
FU-01047
FU-01048
FU-01049

FU(H4DOTC 2.5)-24
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
11) Tighten the two bolts which install the fuel pipes
on the left side of intake manifold.
Tightening torque:
5 N·m (0.5 kgf-m, 3.7 ft-lb)
12) Connect the evaporation hoses to the purge
valve.
NOTE:
Connect the evaporation hoses as shown in the fig-
ure.
13) Connect the evaporation hose and purge valve
to the intake manifold.14) Install the purge control solenoid valve.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
15) Connect the hoses to the purge control sole-
noid valve.
NOTE:
Connect the evaporation hoses as shown in the fig-
ure.
16) Connect the connector to the purge control so-
lenoid valve.
17) Connect the connector to the tumble generator
valve sensor.
(A) To intake duct
(B) To intake manifold
(C) To purge control solenoid valve
(D) To fuel pipe ASSY
FU-00043
FU-01057
(A)
(B)
(D)(C)
FU-01045
(A) To purge valve
(B) To intake manifold
FU-01044
FU-01314(A)
(B)
FU-00617

FU(H4DOTC 2.5)-25
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
18) Connect the connector to the tumble generator
valve actuator.
19) Connect the connector to the fuel injector.
20) Install the throttle body to the intake manifold.
NOTE:
Replace the gasket with a new one.
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
21) Connect the connector to the throttle position
sensor (A) and manifold absolute pressure sensor
(B).22) Install the engine ground terminal to the intake
manifold.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
23) Install the fuel pipe protector RH.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
cracked and the connections are tightened.
FU-00616
FU-01043
FU-01075
FU-01073
(A)
(B)
FU-01041
FU-01042
FU-01040

FU(H4DOTC 2.5)-26
FUEL INJECTION (FUEL SYSTEM)
Engine Coolant Temperature Sensor
4. Engine Coolant Temperature
Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the generator. REMOVAL, Generator.>
3) Drain the engine coolant. DRAINING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
4) Disconnect the connector from the engine cool-
ant temperature sensor.
5) Remove the engine coolant temperature sensor.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
FU-00009
FU-00055

FU(H4DOTC 2.5)-27
FUEL INJECTION (FUEL SYSTEM)
Crankshaft Position Sensor
5. Crankshaft Position Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the bolt which installs the crankshaft
position sensor to cylinder block.
3) Remove the crankshaft position sensor, and dis-
connect the connector from it.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
FU-00009
FU-00056
FU-00057
FU-00058
T

FU(H4DOTC 2.5)-28
FUEL INJECTION (FUEL SYSTEM)
Camshaft Position Sensor
6. Camshaft Position Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from the camshaft po-
sition sensor RH.
3) Remove the camshaft position sensor RH from
the backside of cylinder head.
4) Remove the camshaft position sensor LH same
as RH side.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
FU-00009
FU-01054
FU-01054

FU(H4DOTC 2.5)-29
FUEL INJECTION (FUEL SYSTEM)
Knock Sensor
7. Knock Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intercooler. 10, REMOVAL, Intercooler.>
3) Disconnect the knock sensor connector.
4) Remove the knock sensor from the cylinder
block.
B: INSTALLATION
1) Install the knock sensor to the cylinder block.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
Extraction area of the knock sensor cord must be
positioned at a 60° angle relative to the engine rear.
2) Connect the knock sensor connector.
3) Install the intercooler. INSTALLATION, Intercooler.>
4) Connect the battery ground cable to battery.
FU-00009
FU-00062
FU-00519
(A) Front side
FU-00413
(A)
60
FU-00062
FU-00009

FU(H4DOTC 2.5)-30
FUEL INJECTION (FUEL SYSTEM)
Mass Air Flow and Intake Air Temperature Sensor
8. Mass Air Flow and Intake Air
Temperature Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from mass air flow and
intake air temperature sensor.
3) Remove the mass air flow and intake air temper-
ature sensor.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
1.7 N·m (0.17 kgf-m, 1.3 ft-lb)
FU-00009
FU-00067