2004 SUBARU FORESTER fuel

FU(H4DOTC 2.5)-18
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
 LH SIDE
8) Connect the engine harness connector to the
bulkhead harness connectors.
9) Connect the brake booster vacuum hose.10) Connect the engine coolant hoses to the throt-
tle body.
11) Connect the emission hose to the PCV valve.
12) Connect the pressure hose to the intake duct.
13) Install the power steering pump.
(1) Install the reservoir tank on the bracket.
FU-01310
(A)
FU-00025
FU-00026
FU-00023
FU-01074
FU-00022
FU-00024
FU-00020

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)-20
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
3) Disconnect the connector from the throttle posi-
tion sensor (A) and manifold absolute pressure
sensor (B).
4) Remove the throttle body from the intake mani-
fold.
5) Disconnect the connector from the fuel injector.
6) Disconnect the connector from the tumble gen-
erator valve actuator.7) Disconnect the connector from the tumble gen-
erator valve sensor.
8) Disconnect the connector from the purge control
solenoid valve.
9) Remove the purge control solenoid valve.
10) Disconnect the evaporation hose and purge
valve from the intake manifold.
11) Remove the two bolts which hold the fuel pipes
on the left side of intake manifold.
FU-01073
(A)
(B)
FU-01075
FU-01043
FU-00616
FU-00617
FU-01044
FU-01045
FU-00043

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)-22
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
18) Remove the fuel pipe assembly and pressure
regulator from the intake manifold.
19) Remove the intake duct from the intake manifold.
20) Remove the tumble generator valve assembly
from the intake manifold.
D: ASSEMBLY
NOTE:
Replace the gasket with a new one.
1) Install the tumble generator valve assembly to
the intake manifold.
Tightening torque:
8.25 N·m (0.84 kgf-m, 6.1 ft-lb)2) Install the air intake duct to the intake manifold.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
3) Install the fuel pipe assembly and pressure reg-
ulator to the intake manifold.
Tightening torque:
T1: 5 N·m (0.5 kgf-m, 3.7 ft-lb)
T2: 19 N·m (1.94 kgf-m, 13.7 ft-lb)
4) Install the fuel injector pipe LH.
5) Connect the left side fuel hose to injector pipe,
and tighten the clamp screw.
6) Install the fuel injector pipe RH.
FU-01076
FU-00053
FU-00053
FU-01076
FU-02104
T1
T2
FU-01050

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)-24
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
11) Tighten the two bolts which install the fuel pipes
on the left side of intake manifold.
Tightening torque:
5 N·m (0.5 kgf-m, 3.7 ft-lb)
12) Connect the evaporation hoses to the purge
valve.
NOTE:
Connect the evaporation hoses as shown in the fig-
ure.
13) Connect the evaporation hose and purge valve
to the intake manifold.14) Install the purge control solenoid valve.
Tightening torque:
19 N·m (1.94 kgf-m, 13.7 ft-lb)
15) Connect the hoses to the purge control sole-
noid valve.
NOTE:
Connect the evaporation hoses as shown in the fig-
ure.
16) Connect the connector to the purge control so-
lenoid valve.
17) Connect the connector to the tumble generator
valve sensor.
(A) To intake duct
(B) To intake manifold
(C) To purge control solenoid valve
(D) To fuel pipe ASSY
FU-00043
FU-01057
(A)
(B)
(D)(C)
FU-01045
(A) To purge valve
(B) To intake manifold
FU-01044
FU-01314(A)
(B)
FU-00617

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