2004 SUBARU FORESTER fuel

FU(H4SO)-16
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
16) Disconnect the connector from the oil pressure
switch.
17) Disconnect the connector from the camshaft
position sensor.
18) Remove the EGR pipe from intake manifold.19) Disconnect the fuel hoses from the fuel pipes.
WARNING:
 Do not spill fuel.
 Catch fuel from hoses in a container or cloth.
20) Remove the bolts which hold intake manifold
onto the cylinder heads.
21) Remove the intake manifold.
B: INSTALLATION
1) Install the intake manifold onto the cylinder
heads.
NOTE:
Replace the gaskets with new ones.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
FU-00146
FU-00147
FU-00148
(A) Fuel delivery hose
(B) Fuel return hose
(C) Evaporation hose
(B) (A)
(C)
FU-00259
FU-00260
FU-00260

FU(H4SO)-17
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
2) Connect the fuel hoses.
3) Connect the EGR pipe to intake manifold.
Tightening torque:
34 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
4) Connect the connector to the camshaft position
sensor.
5) Connect the connector to the oil pressure switch.6) Connect the connector to the crankshaft position
sensor.
7) Connect the knock sensor connector.
8) Connect the connectors to the engine coolant
temperature sensor.
9) Install the air cleaner case stay RH and engine
harness bracket, and connect the engine harness
connectors to the bulkhead connectors.
(A) Fuel delivery hose
(B) Fuel return hose
(C) Evaporation hose
(B) (A)
(C)
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FU-00148
FU-00147
FU-00146
FU-00056
FU-00062
FU-00145
FU-00258

FU(H4SO)-18
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
10) Connect the brake booster hose.
11) Connect the engine coolant hose (A) to the
throttle body.
12) Connect the PCV hose to the intake manifold.
13) Connect the spark plug cords to the spark
plugs.
14) Install the power steering pump and reservoir
tank to bracket.
(1) Install the reservoir tank to bracket.(2) Connect the connector to the power steering
pump switch.
(3) Tighten the bolts which install power steer-
ing pump bracket.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 15.9 ft-lb)
(4) Install the power steering pipes onto the
right side intake manifold protector.
(5) Install the front side V-belt. ME(H4SO)-43, INSTALLATION, V-belt.>
FU-00143
FU-00361
(A)(A)
FU-00141
FU-00020
FU-00017
FU-00139
FU-00255

FU(H4SO)-19
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(6) Install the resonator chamber.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
15) Connect the accelerator cable (A). SP(H4SO)-9, INSTALLATION, Accelerator Control
Cable.>
16) Connect the cruise control cable (B). (With cruise
control models)
17) Install the air intake duct and air cleaner case.
Duct.> Cleaner Case.>
18) Connect the connector to the fuel pump relay.19) Connect the battery ground cable to battery.
C: DISASSEMBLY
1) Disconnect the engine ground terminal from the
intake manifold.
2) Disconnect the connector from the ignition coil &
ignitor assembly.
3) Remove the ignition coil & ignitor assembly.
4) Remove the throttle body. 13, REMOVAL, Throttle Body.>
5) Remove the EGR valve. REMOVAL, EGR Valve.>IN-00044
FU-00251
(B)
(A)
FU-00262
FU-00009
FU-00263
FU-00264
FU-00286

FU(H4SO)-20
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
6) Disconnect the pressure regulator vacuum hose
from the intake manifold.
7) Remove the fuel pipe protector LH.
8) Remove the fuel pipe protector RH.
9) Disconnect the connectors from the fuel injec-
tors.10) Disconnect the connector from the purge con-
trol solenoid valve.
11) Disconnect the air by-pass hose from the purge
control solenoid valve.
12) Remove the harness bands (A) and harness
bracket (B) which hold engine harness onto the in-
take manifold.
13) Remove the engine harness from the intake
manifold.
14) Remove the purge control solenoid valve.
15) Remove the bolt which installs injector pipe on
the intake manifold as shown in figure.
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FU-00266
FU-00267
FU-00268
FU-00269
FU-00517(B)(A)
(A)
(A)
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FU-00272

FU(H4SO)-21
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
16) Remove the two bolts which hold fuel pipe as-
sembly on the left side of intake manifold.
17) Remove the fuel injectors.
(1) Remove the fuel injector securing clip.
(2) Remove the fuel injector while lifting up the
fuel injector pipe.
18) Loosen the clamp which holds the front left side
fuel hose to the injector pipe and remove the pipe.19) Loosen the clamp which holds the front right
side fuel hose to the injector pipe and remove the
pipe.
20) Remove the fuel injector pipe.
21) Remove the bolt which installs the fuel pipes on
the intake manifold.
22) Remove the fuel pipe assembly and pressure
regulator, from the intake manifold.
D: ASSEMBLY
1) Install the fuel pipe assembly and pressure reg-
ulator, etc. to the intake manifold.
2) Tighten the bolt which installs the fuel pipes on
the intake manifold.
Tightening torque:
6.4 N
⋅m (0.7 kgf-m, 4.7 ft-lb)
FU-00170
FU-00379
FU-00276
FU-00171
FU-00279
FU-00518
FU-00518

FU(H4SO)-22
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
3) Connect the right side fuel hose to the injector
pipe, and tighten the clamp screw.
4) Install the fuel injector pipe.
5) Connect the left side fuel hose to the injector
pipe, and tighten the clamp screw.
6) Install the fuel injectors.
NOTE:
Replace the O-rings with new ones.NOTE:
Do not forget to install the fuel injector securing clip.
7) Tighten the bolt which installs the injector pipe
on the intake manifold.
Tightening torque:
6.4 N
⋅m (0.7 kgf-m, 4.7 ft-lb)
Tightening torque:
19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
(A) O-ring
(B) Fuel injector
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FU-00171
FU-02097
(A)
(A)(B)
FU-00379
FU-00283
FU-00284

FU(H4SO)-23
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
8) Tighten the two bolts which install the fuel pipe
assembly on the left side of intake manifold.
Tightening torque:
6.4 N
⋅m (0.7 kgf-m, 4.7 ft-lb)
9) Install the purge control solenoid valve.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
10) Connect the hoses to the purge control sole-
noid valve.
NOTE:
Connect the evaporation hose as shown in the fig-
ure.
11) Install the engine harness onto the intake man-
ifold.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.8 ft-lb)12) Connect the connectors to the fuel injectors
and purge control solenoid valve.
13) Hold the engine harness by harness band (A)
and harness bracket (B).
NOTE:
Do not use harness band on harnesses where they
are supposed to be protected by the fuel pipe pro-
tector.
14) Install the fuel pipe protector RH.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
15) Install the fuel pipe protector LH.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
(A) To fuel pipe
(B) To intake manifold
FU-00170
FU-00271
FU-00285
A
B
FU-00517(B)(A)
(A)
(A)
FU-00267
FU-00266