torque SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC)-11
FUEL INJECTION (FUEL SYSTEM)
General Description
6. FUEL FILLER PIPE
(1) Fuel filler pipe ASSY (6) Air vent pipe (11) Fuel filler cap tether
(2) Evaporation hose holder (7) Air vent pipe holder (12) Fuel filler pipe protector
(3) Clip (8) Fuel filler pipe packing
(4) Clamp (9) Fuel filler ringTightening torque: N
⋅m (kgf-m, ft-lb)
(5) Air vent hose (10) Fuel filler capT: 7.5 (0.76, 5.5)
FU-00006
(4)
(2)
(8)
(1)
(12)(11)
(6)
(7)
(9)
(10)
(5)
(3)
(3)
T
T
T
T
T

FU(H4DOTC)-12
FUEL INJECTION (FUEL SYSTEM)
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement. Be careful not to burn yourself, because each
part on the vehicle is hot after running.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical system.
22771AA030 SUBARU SELECT
MONITOR KITTroubleshooting for electrical systems.
 English: 22771AA030 (Without printer)
 German: 22771AA070 (Without printer)
 French: 22771AA080 (Without printer)
 Spanish: 22771AA090 (Without printer)
ST24082AA230
ST22771AA030

FU(H4DOTC)-13
FUEL INJECTION (FUEL SYSTEM)
Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intercooler. 10, REMOVAL, Intercooler.>
3) Disconnect the connector from the throttle posi-
tion sensor (A) and idle air control solenoid valve
(B) and manifold absolute pressure sensor (C).
4) Disconnect the accelerator cable.
5) Disconnect the engine coolant hoses from throt-
tle body.6) Remove the bolts which secure the throttle body
to intake manifold.B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 16.2 ft-lb)
2) Adjust the accelerator cable play. SP(H4SO)-9, INSTALLATION, Accelerator Control
Cable.>
FU-00009
(A)(B)
(C)
FU-00010
FU-00011
FU-00012
FU-00013

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)-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)-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)

FU(H4DOTC)-26
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
12) Connect the evaporation hose to intake mani-
fold.
13) Install the purge control solenoid valve.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.8 ft-lb)
14) Connect the hoses to the purge control sole-
noid valve.
NOTE:
Connect the evaporation hose as shown in the fig-
ure.15) Connect the connector to the purge control so-
lenoid valve.
16) Connect the connector to the tumble generator
valve sensor.
17) Connect the connector to the tumble generator
valve actuator.
18) Connect the connector to fuel injector.
(A) To intake manifold
(B) To purge valve
FU-00042
FU-00041
(A)
(B)
EC-02014
FU-00040
FU-00617
FU-00616
FU-00615

FU(H4DOTC)-27
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
19) Install the throttle body to intake manifold.
NOTE:
Replace the gasket with a new one.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 16.2 ft-lb)
20) Connect the connector to the throttle position
sensor (A), idle air control solenoid valve (B) and
manifold absolute pressure sensor (C).
21) Connect the engine harness with clip (D) to in-
take manifold.22) Install the engine ground cable to intake mani-
fold.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
23) Install the fuel pipe protector RH.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
NOTE:
Bolt (A) is tightened together with ground cable.
Tighten it securely.
FU-00013
FU-00038
(A)
(B) (C)
(D) (D)
FU-00036
FU-00037
FU-00522
(A)

FU(H4DOTC)-28
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
24) Install the fuel pipe protector LH.
NOTE:
Bolt (A) is tightened together with ground cable.
Tighten it securely.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
cracked and the connections are tightened firmly.
(A)
FU-00523