2004 SUBARU FORESTER fuel

FU(H4DOTC 2.5)-50
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
6) Insert the fuel filler hose (A) approx. 35 to 40 mm
(1.38 to 1.57 in) over the lower end of fuel filler pipe
and tighten the clamp.
CAUTION:
Do not allow clips to touch the air vent hose (B)
and rear suspension crossmember.
7) Insert the air vent hose approx. 25 to 30 mm
(0.98 to 1.18 in) into the lower end of air vent pipe
and hold clip.
L = 27.5
±2.5 mm (1.083±0.098 in)
8) Tighten the bolt which holds fuel filler pipe brack-
et on body.
Tightening torque:
7.5 N·m (0.75 kgf-m, 5.4 ft-lb)9) Hold the evaporation hoses onto clip of fuel filler
pipe.
10) Install the fuel filler pipe protector.
11) Install the rear right wheel.
12) Lower the vehicle.
13) Tighten the wheel nuts.
14) Connect the connector to fuel pump relay.
(1) Hose
(2) Clip
(3) Pipe
(A)
(B)
FU-00101
FU-00104
(1)(2)
L/2
L(3)
FU-00100
FU-00098
FU-00097
FU-00096
FU-00262

FU(H4DOTC 2.5)-51
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
15) Connect the battery ground cable to battery.
FU-00009

FU(H4DOTC 2.5)-52
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
24.Fuel Pump
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure.
FUEL PRESSURE, OPERATION, 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.
turn 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 fuel pump as-
sembly onto fuel tank.
13) Take off the fuel pump assembly from fuel tank.
FU-00009
FU-00089
FU-00089
FU-00105
FU-00106
FU-00376
(B)
(A)
FU-00108

FU(H4DOTC 2.5)-53
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
NOTE:
Replace the gaskets with new ones.
(1) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(2) Tighten the nuts in alphabetical sequence
shown in the figure to specified torque.
Tightening torque:
4.4 N
⋅m (0.45 kgf-m, 3.3 ft-lb)
C: INSPECTION
Connect the lead harness to connector terminal of
fuel pump and apply battery power supply to check
whether the pump operates.
WARNING:
 Wipe off the fuel completely.
 Keep the battery as far apart from fuel pump
as possible.
 Be sure to turn the battery supply ON and
OFF on battery side.
 Do not run the fuel pump for a long time un-
der non-load condition.
FU-00109
(A)
(B)
(C)
(D)
(E)
(F)
(G)(H)
FU-003751 2 3
4 5 6

FU(H4DOTC 2.5)-54
FUEL INJECTION (FUEL SYSTEM)
Fuel Level Sensor
25.Fuel Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly.
Pump.>
2) Disconnect the connector from fuel pump brack-
et.
3) Remove the bolt which installs fuel level sensor
on mounting bracket.
B: INSTALLATION
Install in the reverse order of removal.
FU-00111
FU-00112

FU(H4DOTC 2.5)-55
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
26.Fuel Sub Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Drain fuel from the fuel tank. Set a container un-
der the 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 fuel sub level
sensor on fuel tank.
10) Remove the fuel sub level sensor.
FU-00009
FU-00089
FU-00089
FU-00113
FU-00114
FU-00115
FU-00116

FU(H4DOTC 2.5)-56
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
FU-00115

FU(H4DOTC 2.5)-57
FUEL INJECTION (FUEL SYSTEM)
Fuel Filter
27.Fuel Filter
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Release the fuel pressure.
FUEL PRESSURE, OPERATION, Fuel.>
2) Disconnect the fuel delivery hoses from fuel filter.
3) Remove the filter from holder.
B: INSTALLATION
CAUTION:
 If fuel hoses are damaged at the connecting
portion, replace it with a new one.
 If clamps are badly damaged, replace with new
ones.
1) Install in the reverse order of removal.
2) Tighten the hose clamp screws.
Tightening torque:
1.25 N·m (0.13 kgf-m, 0.94 ft-lb)
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.
FU-00118
FU-00118