2004 SUBARU FORESTER fuel cap

FU(H4SO)-37
FUEL INJECTION (FUEL SYSTEM)
Fuel Injector
2. LH SIDE
1) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel flap lid, and remove the fuel filler
cap.
3) Disconnect the ground cable from battery.
4) Remove the two bolts which install the washer
tank on the body.
5) Disconnect the connector from the front window
washer motor.
6) Disconnect the connector from the rear gate
glass washer motor.
7) Disconnect the rear window glass washer hose
from the washer motor, then plug the connection
with a suitable cap.8) Move the washer tank, and secure it away from
the working area.
9) Remove the spark plug cords from the spark
plugs (#2 and #4 cylinders).
10) Remove the fuel pipe protector LH.
11) Disconnect the connector from the fuel injector.
FU-00009
FU-00190
FU-00191
FU-00192
FU-00307
FU-00266
FU-00308

FU(H4SO)-47
FUEL INJECTION (FUEL SYSTEM)
Fuel
19.Fuel
A: OPERATION
1. RELEASING OF FUEL PRESSURE
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
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 sec-
onds.
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.
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(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)-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)-63
FUEL INJECTION (FUEL SYSTEM)
Fuel Delivery, Return and Evaporation Lines
28.Fuel Delivery, Return and Evaporation Lines
A: REMOVAL
1) Set the vehicle on a lift.
2) Release the fuel pressure. Fuel.>
3) Open the fuel filler flap lid and remove fuel filler cap.
4) Remove the floor mat.
5) Remove the fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses.
6) In the engine compartment, detach the fuel de-
livery hose (A), return hose (B) and evaporation
hose (C).
7) Lift-up the vehicle.8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B)
from canister.
FU-00122
(B) (A)
(C)
FU-00374
(A)(B)
FU-00091

ME(H4SO)-30
MECHANICAL
Fuel Pressure
7. Fuel Pressure
A: INSPECTION
WARNING:
Before removing the fuel pressure gauge, re-
lease the fuel pressure.
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
1) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel flap lid, and then remove the fuel
filler cap.
3) Disconnect the fuel delivery hoses from fuel
damper, and then connect the fuel pressure gauge.
4) Connect the connector of fuel pump relay.
5) Start the engine.
6) Measure the fuel pressure while disconnecting
the pressure regulator vacuum hose from intake
manifold.Fuel pressure:
Standard:
284 — 314 kPa (2.9 — 3.2 kg/cm
2, 41 — 46 psi)
7) After connecting the pressure regulator vacuum
hose, measure the fuel pressure.
Fuel pressure:
Standard:
206 — 235 kPa (2.1 — 2.4 kg/cm
2, 30 — 34 psi)
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kg/cm
2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
FU-00208
FU-00262
ME-00198
ME-00198

ME(H4SO)-34
MECHANICAL
Engine Assembly
9. Engine Assembly
A: REMOVAL
1) Set the vehicle on lift arms.
2) Open the front hood fully, and then support with
the front hood stay.
3) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
4) Disconnect the A/C pressure hoses from A/C
compressor.
5) Remove the fuel filler cap.
6) Disconnect the ground cable from battery.
7) Remove the air intake duct and air cleaner case.

Case.>
8) Remove the under cover.
9) Remove the radiator from vehicle. CO(H4SO)-28, REMOVAL, Radiator.>
10) Remove the air cleaner case stay.
 MT model
 AT model11) Disconnect the following connectors and ca-
bles.
(1) Front oxygen (A/F) sensor connector
(2) Rear oxygen sensor connector
(3) Engine ground cable
FU-00009
ME-00204
ME-00205
EX-00029
EX-00030
ME-00206

ME(H4SO)-92
MECHANICAL
Engine Trouble in General
4) Engine stalls after initial
combustion. Engine control system A
Intake system Loosened or cracked intake duct B
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose C
Defective intake manifold gasket B
Defective throttle body gasket B
Dirty air cleaner element C
Fuel line Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
2. Rough idle and engine
stallEngine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve C
Loosened oil filler cap B
Dirty air cleaner element C
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective timing C
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
Improper valve seating B
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Defective rocker cover gasket C
Cooling system Overheating C
Others Malfunction of evaporative emission control system A
Stuck or damaged throttle valve B
Accelerator cable out of adjustment C TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK