torque SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC 2.5)-38
FUEL INJECTION (FUEL SYSTEM)
Rear Oxygen Sensor
15.Rear Oxygen Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Disconnect the connector from the rear oxygen
sensor.
4) Remove the clip by pulling 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 one minute or more.
SUBARU CRC (Part No. 004301003)
6) Remove the rear oxygen sensor.
CAUTION:
When removing the oxygen sensor, wait until
exhaust pipe cools; otherwise, it will damage
exhaust pipe.
B: INSTALLATION
1) Before installing rear oxygen sensor, apply anti-
seize compound only to the threaded portion of rear
oxygen sensor to make the next removal easier.
CAUTION:
Never apply anti-seize compound to protector
of rear oxygen sensor.
Anti-seize compound:
JET LUBE SS-30
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 2.5)-40
FUEL INJECTION (FUEL SYSTEM)
Exhaust Temperature Sensor
16.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 thread-
ed 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 exhaust pipe.
B: INSTALLATION
1) Before installing the exhaust temperature sen-
sor, apply anti-seize compound only to the thread-
ed portion of exhaust temperature sensor to make
the 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) of exhaust temperature sen-
sor 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 2.5)-45
FUEL INJECTION (FUEL SYSTEM)
Fuel
21.Fuel
A: OPERATION
1. RELEASING OF FUEL PRESSURE
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Disconnect the connector from fuel pump relay.
2) Start the engine and run it until it stalls.
3) After the engine stalls, crank it for 5 more seconds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Open the fuel filler flap lid and remove fuel filler
cap.
4) Lift-up the vehicle.5) Drain fuel from the fuel tank.
Set a container under the 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 2.5)-47
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
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.
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 fuel tank cord and
plug the service hole with grommet (B).
9) Set the rear seat and floor mat.
10) Connect the connector to fuel pump relay.
C: INSPECTION
1) Make sure there are no cracks, holes, or other
damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and that connections are tight.
FU-00411
(A)(B)
FU-00091
FU-00092
FU-00093
FU-00411
(B)
(A)
FU-00090
FU-00262

FU(H4DOTC 2.5)-48
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
23.Fuel Filler Pipe
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Set the vehicle on a lift.
2) Release the fuel pressure.
FUEL PRESSURE, OPERATION, Fuel.>
3) Open the fuel filler flap lid and remove fuel filler
cap.
4) Disconnect the ground cable from battery.
5) Remove the screws holding 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 the fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
tank.
10) Tighten the fuel drain plug and then 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 2.5)-50
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 fuel filler pipe brack-
et on body.
Tightening torque:
7.5 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 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-00262

FU(H4DOTC 2.5)-52
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
24.Fuel Pump
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure.
FUEL PRESSURE, OPERATION, Fuel.>
2) Open the fuel filler flap lid and remove fuel filler
cap.
3) Disconnect the ground cable from battery.
4) Lift-up the vehicle.
5) Drain fuel from the fuel tank. Set a container un-
der the 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 floor mat up.
8) Remove the access hole lid.
9) Disconnect the connector from fuel pump.
10) Disconnect the quick connector and then dis-
connect fuel delivery hose.
turn 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 fuel pump as-
sembly 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 2.5)-53
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
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 in alphabetical sequence
shown in the figure to specified torque.
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 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-003751 2 3
4 5 6

FU(H4DOTC 2.5)-55
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
26.Fuel Sub Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Drain fuel from the fuel tank. Set a container un-
der the 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 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 2.5)-56
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