2004 SUBARU FORESTER sensor

FUEL INJECTION (FUEL SYSTEM)
FU(H4SO)
Page
1. General Description ....................................................................................2
2. Throttle Body .............................................................................................13
3. Intake Manifold ..........................................................................................14
4. Engine Coolant Temperature Sensor........................................................25
5. Crankshaft Position Sensor.......................................................................26
6. Camshaft Position Sensor.........................................................................27
7. Knock Sensor ............................................................................................28
8. Throttle Position Sensor ............................................................................29
9. Manifold Absolute Pressure Sensor ..........................................................31
10. Intake Air Temperature Sensor .................................................................32
11. Idle Air Control Solenoid Valve .................................................................33
12. EGR Valve ................................................................................................34
13. Fuel Injector ..............................................................................................35
14. Front Oxygen (A/F) Sensor .......................................................................40
15. Rear Oxygen Sensor.................................................................................42
16. Engine Control Module (ECM) ..................................................................44
17. Main Relay ................................................................................................45
18. Fuel Pump Relay.......................................................................................46
19. Fuel ...........................................................................................................47
20. Fuel Tank ..................................................................................................48
21. Fuel Filler Pipe ..........................................................................................51
22. Fuel Pump .................................................................................................55
23. Fuel Level Sensor .....................................................................................57
24. Fuel Sub Level Sensor ..............................................................................58
25. Fuel Filter ..................................................................................................60
26. Fuel Cut Valve...........................................................................................61
27. Fuel Damper Valve ...................................................................................62
28. Fuel Delivery, Return and Evaporation Lines............................................63
29. Fuel System Trouble in General ...............................................................66

FU(H4SO)-5
FUEL INJECTION (FUEL SYSTEM)
General Description
2. AIR INTAKE SYSTEM
(1) Gasket (5) Throttle bodyTightening torque: N⋅m (kgf-m, ft-lb)
(2) Throttle position sensor (6) Intake air temperature sensorT1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve (7) GrommetT2: 22 (2.2, 15.9)
(4) Manifold absolute pressure sensor (8) Air cleaner case
FU-00247
(2)
(3) (4)
(5) (1)
T1
T1
T1
T2
(8) (6)(7)

FU(H4SO)-6
FUEL INJECTION (FUEL SYSTEM)
General Description
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
(1) Crankshaft position sensor (4) Camshaft position sensor supportTightening torque: N⋅m (kgf-m, ft-lb)
(2) Knock sensorT1: 6.4 (0.65, 4.7)
(3) Camshaft position sensorT2: 24 (2.4, 17.4)
FU-00414
T1
(1)
(2)
T1
T1(3)
(4)
T2

FU(H4SO)-8
FUEL INJECTION (FUEL SYSTEM)
General Description
(1) Heat shield cover (13) Evaporation hose B (25) Fuel return hose B
(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 G
(6) Fuel pump gasket (18) Evaporation hose D (30) Evaporation hose H
(7) Fuel pump ASSY (19) Fuel return hose A
(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 ET2: 7.4 (0.75, 5.4)
(11) Evaporation hose A (23) Fuel pipe ASSYT3: 33 (3.4, 24.3)
(12) Clip (24) Evaporation hose F

FU(H4SO)-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(H4SO)-13
FUEL INJECTION (FUEL SYSTEM)
Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. IN(H4SO)-6, REMOVAL, Air Cleaner Case.>
3) Disconnect the accelerator cable (A).
4) Disconnect the cruise control cable (B). (With
cruise control model)
5) Disconnect the connectors from idle air control
solenoid valve, throttle position sensor and mani-
fold absolute pressure sensor.
6) Disconnect the engine coolant hoses (A) from
the throttle body.7) Remove the bolts (B) which install throttle body
to the intake manifold.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Replace the gasket with a new one.
Tightening torque:
THROTTLE BODY;
22 N
⋅m (2.2 kgf-m, 15.9 ft-lb)
2) Adjust the accelerator cable play. SP(H4SO)-7, ADJUSTMENT, Accelerator Pedal.>
(A) Throttle position sensor
(B) Manifold absolute pressure sensor
(C) Idle air control solenoid valve
FU-00009
FU-00251
(B)
(A)
FU-00378
(B)
(A)(C)
FU-00253
(B)
(B)
(A)(A)

FU(H4SO)-15
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(7) Place the power steering pump on the right
side wheel apron.
8) Disconnect the spark plug cords from the spark
plugs.
9) Disconnect the PCV hose from the intake mani-
fold.
10) Disconnect the engine coolant hose (A) from
the throttle body.
11) Disconnect the brake booster hose.12) Remove the air cleaner case stay RH and en-
gine harness bracket, and disconnect the engine
harness connectors from the bulkhead harness
connectors.
13) Disconnect the connectors from the engine
coolant temperature sensor.
14) Disconnect the knock sensor connector.
15) Disconnect the connector from the crankshaft
position sensor.
FU-00021
FU-00141
FU-00361
(A)(A)
FU-00143
FU-00258
FU-00145
FU-00062
FU-00056

FU(H4SO)-16
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
16) Disconnect the connector from the oil pressure
switch.
17) Disconnect the connector from the camshaft
position sensor.
18) Remove the EGR pipe from intake manifold.19) Disconnect the fuel hoses from the fuel pipes.
WARNING:
 Do not spill fuel.
 Catch fuel from hoses in a container or cloth.
20) Remove the bolts which hold intake manifold
onto the cylinder heads.
21) Remove the intake manifold.
B: INSTALLATION
1) Install the intake manifold onto the cylinder
heads.
NOTE:
Replace the gaskets with new ones.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
FU-00146
FU-00147
FU-00148
(A) Fuel delivery hose
(B) Fuel return hose
(C) Evaporation hose
(B) (A)
(C)
FU-00259
FU-00260
FU-00260