2004 SUBARU FORESTER Intake manifold

FUEL INJECTION (FUEL SYSTEM)
FU(H4SO)
Page
1. General Description ....................................................................................2
2. Throttle Body .............................................................................................13
3. Intake Manifold ..........................................................................................14
4. Engine Coolant Temperature Sensor........................................................25
5. Crankshaft Position Sensor.......................................................................26
6. Camshaft Position Sensor.........................................................................27
7. Knock Sensor ............................................................................................28
8. Throttle Position Sensor ............................................................................29
9. Manifold Absolute Pressure Sensor ..........................................................31
10. Intake Air Temperature Sensor .................................................................32
11. Idle Air Control Solenoid Valve .................................................................33
12. EGR Valve ................................................................................................34
13. Fuel Injector ..............................................................................................35
14. Front Oxygen (A/F) Sensor .......................................................................40
15. Rear Oxygen Sensor.................................................................................42
16. Engine Control Module (ECM) ..................................................................44
17. Main Relay ................................................................................................45
18. Fuel Pump Relay.......................................................................................46
19. Fuel ...........................................................................................................47
20. Fuel Tank ..................................................................................................48
21. Fuel Filler Pipe ..........................................................................................51
22. Fuel Pump .................................................................................................55
23. Fuel Level Sensor .....................................................................................57
24. Fuel Sub Level Sensor ..............................................................................58
25. Fuel Filter ..................................................................................................60
26. Fuel Cut Valve...........................................................................................61
27. Fuel Damper Valve ...................................................................................62
28. Fuel Delivery, Return and Evaporation Lines............................................63
29. Fuel System Trouble in General ...............................................................66

FU(H4SO)-3
FUEL INJECTION (FUEL SYSTEM)
General Description
B: COMPONENT
1. INTAKE MANIFOLD
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T2
T2
T1T1
T1
T1
T1
T1
T5
T4T4
T4
T2
T5
T4
T4
T3
T3
T5
T5
T5T4
T4
T4
T2
T4
(5) (3) (2)
(4)
(1)(4)
(3)
(5) (2)
(19) (20)(6)(7)(8)
(9)
(16)(16)
(16)(19) (21)
(17)(17)(13)
(15)
(17)(12) (11) (18)
(14)
(10)(22)
(18)
(23)

FU(H4SO)-4
FUEL INJECTION (FUEL SYSTEM)
General Description
(1) Intake manifold gasket RH (11) Intake manifold gasket LH (21) Accelerator cable bracket
(2) Fuel injector pipe (12) Fuel pipe protector LH (22) EGR valve
(3) Fuel injector (13) Plug cord holder LH (23) Gasket
(4) O-ring (14) Fuel pipe protector RH
(5) O-ring (15) Fuel pipe ASSYTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Plug (16) Fuel hoseT1: 1.5 (0.15, 1.1)
(7) PCV valve (17) ClipT2: 6.4 (0.7, 4.7)
(8) Purge control solenoid valve (18) ClipT3: 17 (1.7, 12.5)
(9) Nipple (19) Guide pinT4: 19 (1.9, 13.7)
(10) Intake manifold (20) Plug cord holder RHT5: 25 (2.5, 18.1)

FU(H4SO)-5
FUEL INJECTION (FUEL SYSTEM)
General Description
2. AIR INTAKE SYSTEM
(1) Gasket (5) Throttle bodyTightening torque: N⋅m (kgf-m, ft-lb)
(2) Throttle position sensor (6) Intake air temperature sensorT1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve (7) GrommetT2: 22 (2.2, 15.9)
(4) Manifold absolute pressure sensor (8) Air cleaner case
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(2)
(3) (4)
(5) (1)
T1
T1
T1
T2
(8) (6)(7)

FU(H4SO)-13
FUEL INJECTION (FUEL SYSTEM)
Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. IN(H4SO)-6, REMOVAL, Air Cleaner Case.>
3) Disconnect the accelerator cable (A).
4) Disconnect the cruise control cable (B). (With
cruise control model)
5) Disconnect the connectors from idle air control
solenoid valve, throttle position sensor and mani-
fold absolute pressure sensor.
6) Disconnect the engine coolant hoses (A) from
the throttle body.7) Remove the bolts (B) which install throttle body
to the intake manifold.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Replace the gasket with a new one.
Tightening torque:
THROTTLE BODY;
22 N
⋅m (2.2 kgf-m, 15.9 ft-lb)
2) Adjust the accelerator cable play. SP(H4SO)-7, ADJUSTMENT, Accelerator Pedal.>
(A) Throttle position sensor
(B) Manifold absolute pressure sensor
(C) Idle air control solenoid valve
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FU-00251
(B)
(A)
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(B)
(A)(C)
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(B)
(B)
(A)(A)

FU(H4SO)-14
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel flap lid, and remove the fuel filler
cap.
3) Disconnect the ground cable from battery.
4) Remove the air intake duct and air cleaner case.

Case.>
5) Disconnect the accelerator cable (A).
6) Disconnect the cruise control cable (B). (With
cruise control model)
7) Remove the power steering pump and reservoir
tank from bracket.
(1) Remove the resonator chamber. IN(H4SO)-8, REMOVAL, Resonator Chamber.>
(2) Remove the front side V-belt. ME(H4SO)-43, REMOVAL, V-belt.>(3) Remove the bolts which hold power steering
pipes onto the intake manifold protector.
NOTE:
Do not disconnect the power steering hose.
(4) Remove the bolts which install power steer-
ing pump bracket.
(5) Disconnect the connector from the power
steering pump switch.
(6) Remove the power steering tank from the
bracket by pulling it upwards.
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FU-00251
(B)
(A)
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FU-00139
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FU-00020

FU(H4SO)-15
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(7) Place the power steering pump on the right
side wheel apron.
8) Disconnect the spark plug cords from the spark
plugs.
9) Disconnect the PCV hose from the intake mani-
fold.
10) Disconnect the engine coolant hose (A) from
the throttle body.
11) Disconnect the brake booster hose.12) Remove the air cleaner case stay RH and en-
gine harness bracket, and disconnect the engine
harness connectors from the bulkhead harness
connectors.
13) Disconnect the connectors from the engine
coolant temperature sensor.
14) Disconnect the knock sensor connector.
15) Disconnect the connector from the crankshaft
position sensor.
FU-00021
FU-00141
FU-00361
(A)(A)
FU-00143
FU-00258
FU-00145
FU-00062
FU-00056

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)
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FU-00147
FU-00148
(A) Fuel delivery hose
(B) Fuel return hose
(C) Evaporation hose
(B) (A)
(C)
FU-00259
FU-00260
FU-00260