coolant SUBARU FORESTER 2004 Service Manual Online

FUEL INJECTION (FUEL SYSTEM)
FU(H4DOTC)
Page
1. General Description ....................................................................................2
2. Throttle Body .............................................................................................13
3. Intake Manifold ..........................................................................................14
4. Engine Coolant Temperature Sensor........................................................29
5. Crankshaft Position Sensor.......................................................................30
6. Camshaft Position Sensor.........................................................................31
7. AVCS Camshaft Position Sensor ..............................................................32
8. Knock Sensor ............................................................................................33
9. Throttle Position Sensor ............................................................................34
10. Mass Air Flow and Intake Air Temperature Sensor ..................................35
11. Manifold Absolute Pressure Sensor ..........................................................36
12. Idle Air Control Solenoid Valve .................................................................37
13. Fuel Injector ..............................................................................................38
14. Tumble Generator Valve Assembly ..........................................................42
15. Tumble Generator Valve Actuator.............................................................43
16. Wastegate Control Solenoid Valve Assembly ...........................................44
17. Front Oxygen (A/F) Sensor .......................................................................45
18. Rear Oxygen Sensor.................................................................................47
19. Exhaust Temperature Sensor ...................................................................49
20. Engine Control Module (ECM) ..................................................................50
21. Main Relay ................................................................................................51
22. Fuel Pump Relay.......................................................................................52
23. Fuel Pump Control Unit .............................................................................53
24. Fuel ...........................................................................................................54
25. Fuel Tank ..................................................................................................55
26. Fuel Filler Pipe ..........................................................................................58
27. Fuel Pump .................................................................................................62
28. Fuel Level Sensor .....................................................................................64
29. Fuel Sub Level Sensor ..............................................................................65
30. Fuel Filter ..................................................................................................67
31. Fuel Cut Valve...........................................................................................68
32. Fuel Damper Valve ...................................................................................69
33. Fuel Delivery, Return and Evaporation Lines............................................70
34. Fuel System Trouble in General ...............................................................73

FU(H4DOTC)-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 idle air control solenoid valve
(B) and manifold absolute pressure sensor (C).
4) Disconnect the accelerator cable.
5) Disconnect the engine coolant hoses from throt-
tle body.6) Remove the bolts which secure the throttle body
to intake manifold.B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 16.2 ft-lb)
2) Adjust the accelerator cable play. SP(H4SO)-9, INSTALLATION, Accelerator Control
Cable.>
FU-00009
(A)(B)
(C)
FU-00010
FU-00011
FU-00012
FU-00013

FU(H4DOTC)-14
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure. 54, RELEASING OF FUEL PRESSURE, OPERA-
TION, 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) Remove the under cover.
6) Drain the coolant about 3.02 (3.2 US qt, 2.6 Imp
qt).
7) Remove the air cleaner upper cover and air in-
take boot. Cleaner.>
8) Remove the air cleaner element.
9) Remove the intercooler. 10, REMOVAL, Intercooler.>
10) Disconnect the accelerator cable.
11) Remove the coolant filler tank. CO(H4SO)-42, REMOVAL, Coolant Filler Tank.>
12) Remove the power steering pump.(1) Remove the front side V-belt. ME(H4DOTC)-52, REMOVAL, V-belt.>
(2) Disconnect the power steering switch con-
nector.
(3) Remove the bolts which secure the power
steering pipe brackets to intake manifold.
CAUTION:
Do not disconnect the power steering hose.
(4) Remove the bolts which secure the power
steering pump bracket.
(5) Remove the power steering tank from the
bracket by pulling it upward.
FU-00009
FU-00016
FU-00011
FU-00017
FU-00018
FU-00019
FU-00020

FU(H4DOTC)-15
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(6) Place the power steering pump on right side
wheel apron.
13) Disconnect the emission hose from PCV valve.
14) Disconnect the engine coolant hoses from
throttle body.
15) Disconnect the brake booster hose.16) Disconnect the pressure hose from intake duct.
17) Disconnect the engine harness connectors
from bulkhead harness connectors.
18) Disconnect the connectors from the engine
coolant temperature sensor (A), oil pressure switch
(B) and crankshaft position sensor (C).
FU-00021
FU-00022
FU-00012
FU-00023
FU-00024
FU-00025
FU-02086
(A)
(B)
(C)
FU-00027

FU(H4DOTC)-18
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
4) Connect the connector to the oil pressure switch
(B), crankshaft position sensor (C) and engine
coolant temperature sensor (A).
5) Connect the connector to knock sensor.
6) Connect the connector to crankshaft position
sensor.
7) Connect the connector to camshaft position sen-
sor.8) Connect the connector to AVCS camshaft posi-
tion sensor.
9) Connect the connector to oil flow control sole-
noid valve.
10) Connect the connector to ignition coil.
11) Connect the engine harness with clip (A) to the
bracket.
(A)
(B)
(C)
FU-00027
FU-00028
FU-00029
FU-00059
FU-00061
ME-00711
FU-00030
FU-00031
(A)

FU(H4DOTC)-19
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
12) Connect the engine harness connector to bulk-
head harness connectors.
13) Connect the brake booster vacuum hose.
14) Connect the engine coolant hoses to throttle
body.15) Connect the emission hose to PCV valve.
16) Connect the pressure hose to intake duct.
17) Install the power steering pump.
(1) Install the power steering tank on bracket.
(2) Connect the connector to the power steering
pump switch.
FU-00025
FU-02086
FU-00023
FU-00012
FU-00022
FU-00024
FU-00020
FU-00017

FU(H4DOTC)-20
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(3) Install the power steering pump, and then
tighten the bolts.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 16.2 ft-lb)
(4) Install the power steering pipe brackets on
right side intake manifold.
(5) Install the front side V-belt. ME(H4DOTC)-52, REMOVAL, V-belt.>
18) Install the coolant filler tank. 42, INSTALLATION, Coolant Filler Tank.>
19) Connect the accelerator cable. SP(H4SO)-9, INSTALLATION, Accelerator Control
Cable.>
20) Install the intercooler. 11, INSTALLATION, Intercooler.>
21) Install the air cleaner element.
22) Install the air cleaner upper cover and air intake
duct as a unit. TION, Air Cleaner.>23) Connect the connector to the fuel pump relay.
24) Connect the battery ground cable to battery.
25) Lift-up the vehicle.
26) Install the under cover.
27) Fill the coolant. ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
FU-00019
FU-00018
FU-00011
FU-00262
FU-00009

FU(H4DOTC)-29
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.
COOLANT, REPLACEMENT, Engine Coolant.>
4) Disconnect the connector from engine coolant
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

IN(H4DOTC)-5
INTAKE (INDUCTION)
General Description
4. TURBOCHARGER
(1) Oil inlet pipe (7) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Metal gasket (8) Oil outlet pipeT1: 4.4 (0.45, 3.3)
(3) Turbocharger (9) ClipT2: 4.9 (0.50, 3.6)
(4) Water pipe (10) Oil outlet hoseT3: 29 (3.0, 21.7)
(5) Clamp (11) Turbocharger bracket RHT4: 33 (3.4, 24.6)
(6) Engine coolant hose (12) Turbocharger bracket LHT5: 16 (1.6, 11.6)
IN-00249
T5
T1(3)
(8)
(4) (5) (9)
(9)(6)
(12) (1)
(2)
(2)
(2)
(2)
(2)
(7)
(2)
(11)(10)
T4
T2
T3
T4
(2)

IN(H4DOTC)-12
INTAKE (INDUCTION)
Turbocharger
6. Turbocharger
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the center exhaust pipe. EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>
4) Lower the vehicle.
5) Separate the turbocharger joint pipe from turbo-
charger.
6) Disconnect the engine coolant hose which is
connected to coolant filler tank.7) Loosen the clamp which secures turbocharger to
intake duct.
8) Remove the bolt which secures bracket of oil
pipe to turbocharger.
9) Remove the oil pipe from turbocharger.
10) Remove the turbocharger bracket.
11) Disconnect the oil outlet hose from pipe.
12) Take out the turbocharger from engine com-
partment.
FU-00009
IN-00019
IN-00020IN-00074
IN-00022
IN-00023
IN-00024