SUBARU FORESTER 2004 Service Repair Manual

FU(H4SO)-49
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. INSTALLATION, Fuel Delivery, Return and Evapo-
ration 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.
FU-00411
(A)(B)
FU-00091
FU-00092
FU-00093
FU-00411
(B)
(A)
FU-00090

FU(H4SO)-50
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
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-00262

FU(H4SO)-51
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
21.Fuel Filler Pipe
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Set the vehicle on a lift.
2) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, 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(H4SO)-52
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
13) Disconnect the air vent hose from fuel filler
pipe.
14) Remove the bolts which hold fuel filler pipe
bracket on body.
15) Loosen the clamp and separate fuel filler hose
(A) from fuel filler pipe.
16) Move the clip and separate air vent hose (B).
17) Remove the fuel filler pipe to under side of the
vehicle.
18) Remove the air vent pipe together with clip
from body.B: INSTALLATION
1) Hold the fuel filler flap open.
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set cup
(B), and tighten the screws.
NOTE:
If the edges of rubber packing are folded toward in-
side, straighten it with a screwdriver.
4) Install the air vent pipe.
5) Connect the air vent hose to fuel filler pipe.
FU-00099
FU-00100
(A)
(B)
FU-00101
FU-00102
FU-00103
(A)
(C)
(B)
FU-00102
FU-00099

FU(H4SO)-53
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 evaporation
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 (0.76 kgf-m, 5.5 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(H4SO)-54
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
15) Connect the battery ground cable to battery.
FU-00009

FU(H4SO)-55
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
22.Fuel Pump
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, 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. REMOVAL, Fuel Delivery, Return and Evaporation
Lines.>
FU-00009
FU-00089
FU-00089
FU-00105
FU-00106

FU(H4SO)-56
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
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.
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
NOTE:
Always use new gaskets.
(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-00107
(B)(A)
FU-00108
FU-00109
(A)
(B)
(C)
(D)
(E)
(F)
(G)(H)FU-00110
1 2 3
4 5 6

FU(H4SO)-57
FUEL INJECTION (FUEL SYSTEM)
Fuel Level Sensor
23.Fuel Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. FU(H4SO)-55, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.
3) Remove the bolt which installs fuel level sensor
on mounting bracket.
B: INSTALLATION
Install in the reverse order of removal.
FU-00111
FU-00112

FU(H4SO)-58
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
24.Fuel Sub Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
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