engine SUBARU FORESTER 2004 Service Repair Manual

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)-21
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
12) Remove the bolt which hold the fuel injector
pipe onto intake manifold.
 LH SIDE
 RH SIDE13) Remove the harness bracket which holds the
engine harness onto intake manifold.
14) Remove the engine harness from the intake
manifold.
15) Loosen the clamp which holds the front left side
fuel hose to injector pipe, and then remove the pipe
from clamp.
16) Loosen the clamp which holds the right side
fuel hose to injector pipe, and then remove the pipe
from clamp.
17) Remove the bolts which install the fuel pipe on
intake manifold.
FU-01046
FU-01047
FU-01048
FU-01049
FU-00049
FU-01050
FU-01051
FU-01052

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)-25
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
18) Connect the connector to the tumble generator
valve actuator.
19) Connect the connector to the fuel injector.
20) Install the throttle body to the intake manifold.
NOTE:
Replace the gasket with a new one.
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
21) Connect the connector to the throttle position
sensor (A) and manifold absolute pressure sensor
(B).22) Install the engine ground terminal to the intake
manifold.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
23) Install the fuel pipe protector RH.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
cracked and the connections are tightened.
FU-00616
FU-01043
FU-01075
FU-01073
(A)
(B)
FU-01041
FU-01042
FU-01040

FU(H4DOTC 2.5)-26
FUEL INJECTION (FUEL SYSTEM)
Engine Coolant Temperature Sensor
4. Engine Coolant Temperature
Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the generator. REMOVAL, Generator.>
3) Drain the engine coolant. DRAINING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
4) Disconnect the connector from the engine cool-
ant temperature sensor.
5) Remove the engine coolant temperature sensor.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
FU-00009
FU-00055

FU(H4DOTC 2.5)-29
FUEL INJECTION (FUEL SYSTEM)
Knock Sensor
7. Knock Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intercooler. 10, REMOVAL, Intercooler.>
3) Disconnect the knock sensor connector.
4) Remove the knock sensor from the cylinder
block.
B: INSTALLATION
1) Install the knock sensor to the cylinder block.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
Extraction area of the knock sensor cord must be
positioned at a 60° angle relative to the engine rear.
2) Connect the knock sensor connector.
3) Install the intercooler. INSTALLATION, Intercooler.>
4) Connect the battery ground cable to battery.
FU-00009
FU-00062
FU-00519
(A) Front side
FU-00413
(A)
60
FU-00062
FU-00009

FU(H4DOTC 2.5)-35
FUEL INJECTION (FUEL SYSTEM)
Wastegate Control Solenoid Valve
13.Wastegate Control Solenoid
Valve
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the engine harness connector (A)
from bracket.
3) Disconnect the connector (B) from wastegate
control solenoid valve.
4) Remove the bracket from body.
5) Disconnect the pressure hoses (C) from waste-
gate control solenoid valve.6) Remove the wastegate control solenoid valve
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-00366
(A) (B)
FU-00367
(C)
FU-00368
FU-00368

FU(H4DOTC 2.5)-36
FUEL INJECTION (FUEL SYSTEM)
Front Oxygen (A/F) Sensor
14.Front Oxygen (A/F) Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from the front oxygen
(A/F) sensor.
3) Disconnect the engine harness fixed by clip (A)
from the 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 one minute or more.
SUBARU CRC (Part No. 004301003)
8) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the front oxygen (A/F) sensor,
wait until exhaust pipe cools; otherwise, it will
damage exhaust pipe.
FU-00009
FU-01229
FU-00078
(A)(B)
FU-00783
FU-00080

FU(H4DOTC 2.5)-37
FUEL INJECTION (FUEL SYSTEM)
Front Oxygen (A/F) Sensor
B: INSTALLATION
1) Before installing front oxygen (A/F) sensor, ap-
ply anti-seize compound only to the threaded por-
tion of front oxygen (A/F) sensor to make the next
removal easier.
Anti-seize compound:
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to protector
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)
3) Install the service hole cover.
4) Lower the vehicle.
5) Install the front right side wheel.
6) Connect the engine harness to the bracket (B)
using clips (A).7) Connect the connector of front oxygen (A/F)
sensor.
8) Connect the battery ground cable to battery.
FU-00080
FU-00783
FU-00078
(A)(B)
FU-01229
FU-00009

FU(H4DOTC 2.5)-41
FUEL INJECTION (FUEL SYSTEM)
Engine Control Module (ECM)
17.Engine Control Module (ECM)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the lower inner trim of the passenger
side.
3) Detach the floor mat of the front passenger seat.
4) Remove the protect cover.
5) Remove the nuts (A) which hold ECM to the
bracket.
6) Remove the clip (B) from the bracket.
7) Disconnect the ECM connectors and take out
the ECM.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
When replacing ECM, be careful not to use the
wrong spec. ECM to avoid any damage to the fuel
injection system.
FU-00009
FU-01029
(A)
(A)
(B)
FU-00316