2004 SUBARU FORESTER fuel

FU(H4DOTC 2.5)-42
FUEL INJECTION (FUEL SYSTEM)
Main Relay
18.Main Relay
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the glove box. AL, Glove Box.>
3) Remove the bolt which holds the main relay
bracket on the body.
4) Disconnect the connectors from the main relay.
B: INSTALLATION
Install in the reverse order of removal.
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FU-00317

FU(H4DOTC 2.5)-43
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump Relay
19.Fuel Pump Relay
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the glove box. AL, Glove Box.>
3) Remove the bolt which holds fuel pump relay
bracket on the body.
4) Disconnect the connector from the fuel pump re-
lay.
5) Remove the fuel pump relay from the mounting
bracket.
B: INSTALLATION
Install in the reverse order of removal.
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FU(H4DOTC 2.5)-44
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump Control Unit
20.Fuel Pump Control Unit
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the rear quarter trim. MOVAL, Rear Quarter Trim.>
3) Disconnect the connector from the fuel pump con-
trol unit.
4) Remove the fuel pump control unit.
B: INSTALLATION
Install in the reverse order of removal.
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FU(H4DOTC 2.5)-45
FUEL INJECTION (FUEL SYSTEM)
Fuel
21.Fuel
A: OPERATION
1. RELEASING OF FUEL PRESSURE
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
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 seconds.
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 on the floor.
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)
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FU(H4DOTC 2.5)-46
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
22.Fuel Tank
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Set the vehicle on a lift.
2) Release the fuel pressure.
FUEL PRESSURE, OPERATION, Fuel.>
3) Drain fuel from the fuel tank.
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 fuel tank cord
on floor panel into under the 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 quick connec-
tor. Delivery, Return and Evaporation Lines.>
11) Disconnect the fuel hoses.
12) Support the fuel tank with transmission jack,
and remove the bolts from bands and dismount fuel
tank from the vehicle.
WARNING:
A helper is required to perform this work.
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
(B)
(A)
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(A)
(B)
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FU(H4DOTC 2.5)-47
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
WARNING:
A helper is required to perform this work.
3) Connect the two-way valve hose (A) to two-way
valve and connect the canister hose (B) to canister.
4) Connect the fuel filler hose and air vent hose.
5) Connect the fuel hoses, and secure them with
clips and quick connector.
Fuel Delivery, Return and Evaporation Lines.>6) Tighten the band mounting bolts.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
7) Install the rear crossmember. INSTALLATION, Rear Crossmember.>
8) Connect the connector (A) to fuel tank cord and
plug the service hole with grommet (B).
9) Set the rear seat and floor mat.
10) Connect the connector to fuel pump relay.
C: INSPECTION
1) Make sure there are no cracks, holes, or other
damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and that connections are tight.
FU-00411
(A)(B)
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(B)
(A)
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FU(H4DOTC 2.5)-48
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
23.Fuel Filler Pipe
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Set the vehicle on a lift.
2) Release the fuel pressure.
FUEL PRESSURE, OPERATION, 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.
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FU(H4DOTC 2.5)-49
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
13) Disconnect the air vent hose from fuel filler
pipe.
14) Remove the bolts which hold fuel filler pipe
bracket on body.
15) Loosen the clamp and separate fuel filler hose
(A) from fuel filler pipe.
16) Move the clip and separate air vent hose (B).
17) Remove the fuel filler pipe to under side of the
vehicle.
18) Remove the air vent pipe together with clip
from body.B: INSTALLATION
1) Hold the fuel filler flap open.
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set cup
(B), and tighten the screws.
NOTE:
If the edges of rubber packing are folded toward in-
side, straighten it with a screwdriver.
4) Install the air vent pipe.
5) Connect the air vent hose to fuel filler pipe.
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(A)
(B)
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(A)
(C)
(B)
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