torque SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC)-41
FUEL INJECTION (FUEL SYSTEM)
Fuel Injector
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
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.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
FU-00044
FU-00618
(A)
FU-00523

FU(H4DOTC)-42
FUEL INJECTION (FUEL SYSTEM)
Tumble Generator Valve Assembly
14.Tumble Generator Valve As-
sembly
A: REMOVAL
1) Release the fuel pressure. 54, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel filler flap lid, and then remove the
fuel filler cap.
3) Disconnect the ground cable from battery.
4) Remove the intake manifold. FU(H4DOTC)-14, REMOVAL, Intake Manifold.>
5) Disconnect the connector from tumble generator
valve sensor.
6) Disconnect the connector from tumble generator
valve actuator.
7) Remove the fuel injector. 38, REMOVAL, Fuel Injector.>8) Remove the tumble generator valve body from
intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Always use new gaskets.
Tightening torque:
8.25 N
⋅m (0.84 kgf-m, 6.1 ft-lb)
FU-00009
FU-00617
FU-00616
FU-00053
FU-00053

FU(H4DOTC)-44
FUEL INJECTION (FUEL SYSTEM)
Wastegate Control Solenoid Valve Assembly
16.Wastegate Control Solenoid
Valve Assembly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from wastegate con-
trol solenoid valve assembly.
3) Disconnect the engine harness connector from
bracket.
4) Remove the bracket from body.
5) Disconnect the pressure hoses (C) from waste-
gate control solenoid valve assembly.6) Remove the wastegate control solenoid valve
assembly from bracket.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.5 N
⋅m (0.66 kgf-m, 4.8 ft-lb)
FU-00009
FU-02087
FU-00367
(C)
FU-00368
FU-00368

FU(H4DOTC)-45
FUEL INJECTION (FUEL SYSTEM)
Front Oxygen (A/F) Sensor
17.Front Oxygen (A/F) Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from front oxygen (A/
F) sensor.
3) Disconnect the engine harness fixed by clip (A)
from bracket (B).
4) Remove the front right side wheel.
5) Lift-up the vehicle.
6) Remove the service hole cover.7) Apply SUBARU CRC or its equivalent to the
threaded portion of front oxygen (A/F) sensor, and
leave it for 1 minute or more.
SUBARU CRC (Part No. 004301003)
8) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the oxygen (A/F) sensor, wait
until the exhaust pipe cools, otherwise it will
damage the exhaust pipe.
B: INSTALLATION
1) Before installing the front oxygen (A/F) sensor,
apply anti-seize compound only to the threaded
portion of front oxygen (A/F) sensor to make next
removal easier.
Anti-seize compound:
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to the protec-
tor of front oxygen (A/F) sensor.
2) Install the front oxygen (A/F) sensor.
Tightening torque:
30 N
⋅m (3.1 kgf-m, 22.1 ft-lb)
FU-00009
FU-02088
FU-00078
(A)(B)
FU-00079
FU-00080
FU-00080

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)-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)-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)-56
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
WARNING:
A helper is required to perform this work.
3) Connect the two-way valve hose (A) to two-way
valve and connect the canister hose (B) to canister.
4) Connect the fuel filler hose and air vent hose.5) Connect the fuel hoses, and secure them with
clips and quick connector. 71, INSTALLATION, Fuel Delivery, Return and
Evaporation Lines.>
6) Tighten the band mounting bolts.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
7) Install the rear crossmember. INSTALLATION, Rear Crossmember.>
8) Connect the connector (A) to the fuel tank cord,
and plug the service hole with grommet (B).
9) Set the rear seat and floor mat.
FU-00411
(A)(B)
FU-00091
FU-00092
FU-00093
FU-00411
(B)
(A)
FU-00090

FU(H4DOTC)-58
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
26.Fuel Filler Pipe
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) Open the fuel filler flap lid and remove the fuel
filler cap.
4) Disconnect the ground cable from battery.
5) Remove the screws holding the packing in place.
6) Loosen the rear right side wheel nuts.
7) Lift-up the vehicle.
8) Remove the rear right side wheel.9) Drain fuel from fuel tank. Set a container under
vehicle and remove the drain plug from fuel tank.
10) Tighten the fuel drain plug, and install the front
right side tank cover.
Tightening torque:
26 N
⋅m (2.7 kgf-m, 19.2 ft-lb)
11) Remove the fuel filler pipe protector.
12) Separate the evaporation hoses from clip of
fuel filler pipe.
FU-00009
FU-00095
FU-00096
FU-00089
FU-00089
FU-00097
FU-00098

FU(H4DOTC)-60
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
6) Insert the fuel filler hose (A) approx. 35 to 40 mm
(1.38 to 1.57 in) over the lower end of fuel filler pipe
and tighten the clamp.
CAUTION:
Do not allow clips to touch the air vent hose (B)
and rear suspension crossmember.
7) Insert the air vent hose approx. 25 to 30 mm
(0.98 to 1.18 in) into the lower end of air vent pipe
and hold clip.
L = 27.5
±2.5 mm (1.083±0.098 in)
8) Tighten the bolt which holds the fuel filler pipe
bracket on body.
Tightening torque:
7.4 N
⋅m (0.75 kgf-m, 5.4 ft-lb)9) Hold the evaporation hoses onto clip of fuel filler
pipe.
10) Install the fuel filler pipe protector.
11) Install the rear right wheel.
12) Lower the vehicle.
13) Tighten the wheel nuts.
14) Connect the connector to the fuel pump relay.
(1) Hose
(2) Clip
(3) Pipe
(A)
(B)
FU-00101
FU-00104
(1)(2)
L/2
L(3)
FU-00100
FU-00098
FU-00097
FU-00096
FU-00871