2004 SUBARU FORESTER fuel tank removal

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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(B)
(A)
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FU-00139
FU-00017
FU-00020

FU(H4SO)-35
FUEL INJECTION (FUEL SYSTEM)
Fuel Injector
13.Fuel Injector
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure.
PRESSURE, OPERATION, Fuel.>
2) Open the fuel flap lid, and remove the fuel filler
cap.
3) Disconnect the ground cable from battery.
4) Remove the resonator chamber. IN(H4SO)-8, REMOVAL, Resonator Chamber.>
5) Remove the spark plug cords from the spark
plugs (#1 and #3 cylinders).6) Remove the power steering pump and reservoir
tank from the brackets.
(1) Remove the front side V-belt. ME(H4SO)-43, REMOVAL, V-belt.>
(2) Remove the bolts which hold the power
steering pipes onto the intake manifold protec-
tor.
(3) Remove the bolts which install the power
steering pump to the bracket.
(4) Disconnect the connector from the power
steering pump switch.
FU-00009
FU-00302
FU-00255
FU-00139
FU-00017

FU(H4SO)-48
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
20.Fuel Tank
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Set the vehicle on a lift.
2) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
3) Drain fuel from the fuel tank. 47, DRAINING FUEL, 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. ery, 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)
(A)
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(A)
(B)
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FU(H4SO)-51
FUEL INJECTION (FUEL SYSTEM)
Fuel Filler Pipe
21.Fuel Filler Pipe
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Set the vehicle on a lift.
2) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, 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-00095
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FU(H4SO)-55
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
22.Fuel Pump
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, 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. REMOVAL, Fuel Delivery, Return and Evaporation
Lines.>
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FU(H4SO)-56
FUEL INJECTION (FUEL SYSTEM)
Fuel Pump
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.
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
NOTE:
Always use new gaskets.
(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.
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(B)(A)
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FU-00109
(A)
(B)
(C)
(D)
(E)
(F)
(G)(H)FU-00110
1 2 3
4 5 6

FU(H4SO)-58
FUEL INJECTION (FUEL SYSTEM)
Fuel Sub Level Sensor
24.Fuel Sub Level Sensor
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
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.
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FU(H4SO)-61
FUEL INJECTION (FUEL SYSTEM)
Fuel Cut Valve
26.Fuel Cut Valve
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Remove the fuel tank. REMOVAL, Fuel Tank.>
2) Move the clip and disconnect the evaporation
hose from fuel cut valve.
3) Remove the bolts which install fuel cut valve.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N
⋅m (0.45 kgf-m, 3.3 ft-lb)
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FU-00120