torque SUBARU FORESTER 2004 Service Repair Manual

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)-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

FU(H4DOTC 2.5)-11
FUEL INJECTION (FUEL SYSTEM)
General Description
6. FUEL FILLER PIPE
(1) Fuel filler pipe ASSY (6) Air vent pipe (11) Filler cap tether
(2) Evaporation hose holder (7) Air vent pipe holder (12) Filler pipe protector
(3) Clip (8) Filler pipe packing
(4) Clamp (9) Filler ringTightening torque: N·m (kgf-m, ft-lb)
(5) Air vent hose (10) Filler capT: 7.5 (0.76, 5.53)
FU-00006
(4)
(2)
(8)
(1)
(12)(11)
(6)
(7)
(9)
(10)
(5)
(3)
(3)
T
T
T
T
T

FU(H4DOTC 2.5)-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 negative
terminal 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 2.5)-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 manifold absolute pressure sen-
sor (B).
4) Disconnect the engine coolant hoses from the
throttle body.
5) Remove the bolts which secure the throttle body
to intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
FU-00009
FU-01073
(A)
(B)
FU-01074
FU-01075

FU(H4DOTC 2.5)-17
FUEL INJECTION (FUEL SYSTEM)
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, 18.1 ft-lb)
2) Connect the fuel delivery hose, return hose and
evaporation hose.
3) Connect the connector to the oil pressure switch
(B), crankshaft position sensor (C) and engine cool-
ant temperature sensor (A).4) Connect the connector to the knock sensor.
5) Connect the connector to the camshaft position
sensor.
6) Connect the connector to the ignition coil.
7) Connect the engine harness with clip (A) to the
bracket.
 RH SIDE
FU-01039
FU-00032
(A)
(B)
(C)
FU-00027
FU-00028
FU-01038
FU-00030
FU-01309 (A)

FU(H4DOTC 2.5)-19
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(2) Connect the connector to the power steering
pump switch.
(3) Install the power steering pump, and tighten
the bolts.
Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)
(4) Install the power steering pipe brackets on
the intake manifold RH.
(5) Install the front side V-belt. ME(H4DOTC)-52, INSTALLATION, V-belt.>
14) Install the coolant filler tank. 42, INSTALLATION, Coolant Filler Tank.>
15) Install the intercooler. 11, INSTALLATION, Intercooler.>
16) Install the air cleaner element.
17) Install the air cleaner upper cover and air intake
duct as a unit. TION, Air Cleaner.>18) Connect the connector to the fuel pump relay.
19) Connect the battery ground cable to battery.
20) Lift up the vehicle.
21) Install the under cover.
22) Fill the engine coolant. FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
C: DISASSEMBLY
1) Remove the fuel pipe protector RH.
2) Remove the engine ground terminal from the in-
take manifold.
FU-00017
FU-00019
FU-00018
ME-00649
FU-01040
FU-01041
FU-01042

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