2004 SUBARU FORESTER fuel tank removal

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.
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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.>
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FU(H4DOTC)-55
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
25.Fuel Tank
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Set the vehicle on a lift.
2) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
3) Drain fuel from fuel tank. 54, DRAINING FUEL, OPERATION, Fuel.>
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to
rear harness.
6) Push the grommet (B) which holds the fuel tank
cord on floor panel down under body.
7) Remove the rear crossmember. REMOVAL, Rear Crossmember.>
8) Disconnect the two-way valve hose (A) from
two-way valve, and disconnect the canister hose
(B) from canister.9) Loosen the clamp and disconnect the fuel filler
hose and air vent hose from fuel filler pipe.
10) Move the clips and disconnect the quick con-
nector. Delivery, Return and Evaporation Lines.>
11) Disconnect the fuel hoses.
12) Support the fuel tank with transmission jack, re-
move the bolts from bands, and then dismount the
fuel tank from vehicle.
WARNING:
A helper is required to perform this work.
(B)
(A)
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(A)
(B)
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FU(H4DOTC)-58
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
26.Fuel Filler Pipe
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Set the vehicle on a lift.
2) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
3) Open the fuel filler flap lid and remove the fuel
filler cap.
4) Disconnect the ground cable from battery.
5) Remove the screws holding the 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 fuel tank. Set a container under
vehicle and remove the drain plug from fuel tank.
10) Tighten the fuel drain plug, and 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.
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FU(H4DOTC)-62
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
27.Fuel Pump
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, 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) Drain fuel from fuel tank. Set a container under
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 the floor mat up.
8) Remove the access hole lid.
9) Disconnect the connector from fuel pump.
10) Disconnect the quick connector, and discon-
nect the fuel delivery hose. 70, Fuel Delivery, Return and Evaporation Lines.>
11) Move the clips, and then disconnect the fuel re-
turn hose (A) and jet pump hose (B).
12) Remove the nuts which install the fuel pump
assembly onto fuel tank.
13) Take off the fuel pump assembly from fuel tank.
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(B)
(A)
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FU(H4DOTC)-65
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
29.Fuel Sub Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Drain fuel from fuel tank. Set a container under
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 the fuel sub level
sensor on fuel tank.
10) Remove the fuel sub level sensor.
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FU(H4DOTC)-68
FUEL INJECTION (FUEL SYSTEM)
Fuel Cut Valve
31.Fuel Cut Valve
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Remove the fuel tank. 55, REMOVAL, Fuel Tank.>
2) Move the clip and disconnect the evaporation
hose from fuel cut valve.
3) Remove the bolts which install the fuel cut valve.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N
⋅m (0.45 kgf-m, 3.3 ft-lb)
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ME(H4DOTC)-41
MECHANICAL
Engine Assembly
9. Engine Assembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Open the front hood fully, and then support with
the hood stay.
3) Collect the refrigerant from A/C system.

4) Release the fuel pressure.
(1) Disconnect the fuel pump relay connector.
(2) Start the engine, and run until stalls.
(3) After the engine stalls, crank it for 5 seconds
more.
(4) Turn the ignition switch to OFF.
5) Remove the filler cap.
6) Disconnect the ground cable from battery.
7) Remove the radiator from vehicle. CO(H4SO)-28, REMOVAL, Radiator.>
8) Remove the coolant filler tank. CO(H4SO)-42, REMOVAL, Coolant Filler Tank.>
9) Disconnect the A/C pressure hoses from A/C
compressor.10) Remove the intercooler. 10, REMOVAL, Intercooler.>
11) Disconnect the following connectors and cable.
(1) Engine harness connector
(2) Engine ground terminal
(3) Disconnect the right and left side engine
ground cables.
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