torque SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC)-62
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
27.Fuel Pump
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the ground cable from battery.
4) Lift-up the vehicle.
5) Drain fuel from 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)7) Raise the rear seat and turn the floor mat up.
8) Remove the access hole lid.
9) Disconnect the connector from fuel pump.
10) Disconnect the quick connector, and discon-
nect the fuel delivery hose. 70, Fuel Delivery, Return and Evaporation Lines.>
11) Move the clips, and then disconnect the fuel re-
turn hose (A) and jet pump hose (B).
12) Remove the nuts which install the fuel pump
assembly onto fuel tank.
13) Take off the fuel pump assembly from fuel tank.
FU-00009
FU-00089
FU-00089
FU-00105
FU-00106
FU-00376
(B)
(A)
FU-00108

FU(H4DOTC)-63
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
B: INSTALLATION
NOTE:
Replace the gaskets with new ones.
(1) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(2) Tighten the nuts to specified torque in alpha-
betical sequence as shown in the figure.
Tightening torque:
4.4 N
⋅m (0.45 kgf-m, 3.3 ft-lb)
C: INSPECTION
Connect the lead harness to connector terminal of
fuel pump, and then apply battery power supply to
check whether the pump operates.
WARNING:
 Wipe off the fuel completely.
 Keep the battery as far apart from fuel pump
as possible.
 Be sure to turn the battery supply ON and
OFF on battery side.
 Do not run the fuel pump for a long time un-
der non-load condition.
FU-00109
(A)
(B)
(C)
(D)
(E)
(F)
(G)(H)
FU-00375
1 2 3
4 5 6

FU(H4DOTC)-65
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
29.Fuel Sub Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Drain fuel from fuel tank. Set a container under
vehicle and remove the drain plug from fuel tank.
4) Tighten the fuel drain plug.
Tightening torque:
26 N
⋅m (2.7 kgf-m, 19.2 ft-lb)
5) Remove the rear seat.6) Remove the service hole cover.
7) Disconnect the connector from fuel sub level
sensor.
8) Disconnect the fuel jet pump hose.
9) Remove the bolts which install the fuel sub level
sensor on fuel tank.
10) Remove the fuel sub level sensor.
FU-00009
FU-00089
FU-00089
FU-00113
FU-00114
FU-00115
FU-00116

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

EC(H4DOTC)-2
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
General Description
1. General Description
A: 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 your hands, 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.

EC(H4DOTC)-6
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Canister
5. Canister
A: REMOVAL
1) Lift-up the vehicle.
2) Loosen the two clamps which hold two canister
hoses, and disconnect the three evaporation hoses
from canister.
3) Remove the canister from body.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
23 N
⋅m (2.3 kgf-m, 17 ft-lb)
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
EC-00003
EC-00004
EC-00004

EC(H4DOTC)-7
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Purge Control Solenoid Valve
6. Purge Control Solenoid Valve
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector and hoses from purge
control solenoid valve.
3) Remove the bolt which installs the purge control
solenoid valve onto intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)NOTE:
Connect the evaporation hoses as shown in the fig-
ure.
C: INSPECTION
Make sure the hoses are not cracked or loose.
FU-00009
EC-00005
EC-00005
(A) To intake manifold
(B) To purge valve
(A)
(B)
EC-02014

IN(H4DOTC)-2
INTAKE (INDUCTION)
General Description
1. General Description
A: COMPONENT
1. AIR CLEANER
(1) Mass air flow and intake air tem-
perature sensor(7) Air cleaner lower case (14) Cushion
(8) Cushion rubber
(2) Air cleaner upper cover (9) Air intake ductTightening torque: N
⋅m (kgf-m, ft-lb)
(3) Air cleaner element (10) Resonator chamber ASSYT1: 7.5 (0.76, 5.5)
(4) Spacer (11) Cushion rubberT2: 33 (3.4, 24.6)
(5) Bushing (12) ClampT3: 2.5 (0.25, 1.8)
(6) Clip (13) Air intake bootT4: 1.7 (0.17, 1.2)
(3)
(12)
(12) (13)
(6)
(6)(7)
(4)
(5) (8)
(14)
(11)
(10)T3
T3
T2
(9)
T1
T1
T1
T1
T4
(2)
(1)
IN-00001