Subaru forester 2001 Service Manual

Subaru forester 2001 Service Manual

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2001 FORESTER SERVICE MANUAL
ENGINE2 SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
G8050GE3

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Summary of Contents for Subaru forester 2001

  • Page 1 When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.
  • Page 2: Table Of Contents

    FUEL INJECTION (FUEL SYSTEMS) FU(DOHC TURBO) Page General Description..................2 Throttle Body .....................14 Intake Manifold ..................15 Engine Coolant Temperature Sensor............29 Crankshaft Position Sensor...............30 Camshaft Position Sensor.................31 Knock Sensor ....................32 Throttle Position Sensor................33 Mass Air Flow and Intake Air Temperature Sensor ........34 Pressure Sensor..................35 Idle Air Control Solenoid Valve ..............36 Fuel Injector....................37...
  • Page 3: General Description

    GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 1. General Description S185001 A: SPECIFICATIONS S185001E49 Model Capacity (15.9 US gal, 13.2 Imp gal) Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 450 — 677 kPa (4.59 — 6.9 kg/cm , 65.27 —...
  • Page 4 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) MEMO: FU(DOHC TURBO)-3...
  • Page 5 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) B: COMPONENT S185001A05 1. INTAKE MANIFOLD S185001A0501 S2M2173A FU(DOHC TURBO)-4...
  • Page 6 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Fuel pipe ASSY (13) Accelerator cable bracket Tightening torque: N·m (kgf-m, ft-lb) (2) Fuel hose (14) Fuel injector 5 (0.50, 3.7) (3) Clip (15) Insulator 6.4 (0.65, 4.7) (4) Purge control solenoid valve (16) Fuel injector pipe 8.25 (0.84, 6.1) (5) Vacuum hose...
  • Page 7 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 2. AIR INTAKE SYSTEM S185001A0502 EN0779 (1) Gasket (5) Pressure sensor Tightening torque: N·m (kgf-m, ft-lb) (2) Throttle position sensor 1.6 (0.16, 1.2) (3) Idle air control solenoid valve 2.8 (0.29, 2.1) (4) Throttle body 22 (2.2, 16) FU(DOHC TURBO)-6...
  • Page 8 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS S185001A0503 EN0780 (1) Crankshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) (2) Knock sensor 6.4 (0.65, 4.7) (3) Camshaft position sensor 24 (2.4, 17.4) FU(DOHC TURBO)-7...
  • Page 9 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 4. FUEL TANK S185001A0504 S2M2152A FU(DOHC TURBO)-8...
  • Page 10 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Heat sealed cover (13) Evaporation hose B (25) Fuel return hose B (2) Fuel tank band (14) Joint pipe (26) Fuel sub level sensor gasket (3) Protector LH (15) Evaporation hose C (27) Jet pump filter (4) Protector RH (16) Evaporation pipe ASSY (28) Fuel sub level sensor...
  • Page 11 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 5. FUEL LINE S185001A0505 S2M2153A FU(DOHC TURBO)-10...
  • Page 12 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) (1) Clip (13) Canister hose A (25) Front canister bracket (2) Fuel delivery hose A (14) Canister (26) Evaporation hose B (3) Fuel filter bracket (15) Canister bracket plate (27) Roll over valve bracket (4) Fuel filter holder (16) Cushion (28) Roll over valve...
  • Page 13 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) 6. FUEL FILLER PIPE S185001A0506 S2M2245A (1) Fuel filter pipe ASSY (6) Air vent pipe (11) Fuel pipe protector (2) Evaporation hose holder (7) Air vent pipe holder (3) Clamp (8) Filler pipe packing Tightening torque: N·m (kgf-m, ft-lb) (4) Clamp (9) Filler ring...
  • Page 14 GENERAL DESCRIPTION Fuel Injection (Fuel Systems) ¼ Be careful not to burn your hands, because each C: CAUTION S185001A03 part on the vehicle is hot after running. ¼ Wear working clothing, including a cap, protec- ¼ Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
  • Page 15: Throttle Body

    THROTTLE BODY Fuel Injection (Fuel Systems) 2. Throttle Body 5) Disconnect engine coolant hoses from throttle S185010 body. A: REMOVAL S185010A18 1) Disconnect battery ground cable. EN0784 6) Remove bolts which secure throttle body to intake manifold. G6M0095 2) Remove intercooler.
  • Page 16: Intake Manifold

    INTAKE MANIFOLD Fuel Injection (Fuel Systems) 3. Intake Manifold (1) Remove front side V-belt. <Ref. S185034 ME(DOHC TURBO)-44, REMOVAL, V-belt.> A: REMOVAL (2) Disconnect the power steering switch con- S185034A18 nector. 1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>...
  • Page 17 INTAKE MANIFOLD Fuel Injection (Fuel Systems) (5) Remove power steering tank from the 14) Disconnect brake booster hose. bracket by pulling it upward. EN0204 EN0361 15) Disconnect Pressure hose from intake duct. (6) Place power steering pump on the right side wheel apron.
  • Page 18 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 17) Disconnect connectors from engine coolant 21) Remove harness secured by clip (A) from the temperature sensor (A), oil pressure switch (B) and bracket. crankshaft position sensor (C). S2M2256A EN0790 22) Disconnect fuel delivery hose, return hose and 18) Disconnect knock sensor connector.
  • Page 19 INTAKE MANIFOLD Fuel Injection (Fuel Systems) Tightening torque: 5) Connect connector to camshaft position sensor. 25 N·m (2.5 kgf-m, 18.1 ft-lb) B2M1251 EN0792 6) Connect connector to ignition coil. 2) Connect fuel delivery hose, return hose, and evaporation hose. EN0854 7) Secure harness to the bracket with clip (A).
  • Page 20 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 8) Connect engine harness connector to bulkhead 11) Connect emission hose to PCV valve. harness connectors. EN0789 EN0788 12) Connect pressure hose to intake duct. S2M2260 EN0787 9) Connect brake booster vacuum hose. 13) Install power steering pump on bracket. (1) Install power steering tank on bracket.
  • Page 21 INTAKE MANIFOLD Fuel Injection (Fuel Systems) (3) Install power steering pump, and tighten 19) Connect connector to fuel pump relay. bolts. Tightening torque: 20.1 N·m (2.05 kgf-m, 14.8 ft-lb) S2M0093 20) Connect battery ground cable. 21) Lift up vehicle. H2M1954 22) Install under cover.
  • Page 22 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 5) Remove throttle body from intake manifold. C: DISASSEMBLY S185034A06 1) Remove fuel pipe protector. EN0785 6) Disconnect connector from fuel injector. EN0794 2) Remove engine ground terminal from intake manifold. EN0798 7) Disconnect connector from tumble generator valve actuator.
  • Page 23 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 9) Disconnect connector from purge control sole- 13) Remove two bolts which hold fuel pipes on the noid valve. left side of intake manifold. EN0801 EN0805 10) Remove purge control solenoid valve. 14) Remove bolt which hold fuel injector pipe onto intake manifold.
  • Page 24 INTAKE MANIFOLD Fuel Injection (Fuel Systems) ¼ RH SIDE 18) Loosen clamp which holds front left side fuel hose to injector pipe and remove the pipe from clamp. EN0808 EN0812 19) Remove fuel injector pipe LH. 20) Remove bolts which installs fuel pipe on intake manifold.
  • Page 25 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 23) Remove tumble generator valve assembly 3) Install fuel pipe assembly and pressure from intake manifold. regulator, to intake manifold. Tightening torque: 5 N·m (0.51 kgf-m, 3.69 ft-lb) EN0815 D: ASSEMBLY EN0813 S185034A02 4) Install fuel injector pipe LH. NOTE: 5) Connect left side fuel hose to injector pipe, and Replace gasket with a new one.
  • Page 26 INTAKE MANIFOLD Fuel Injection (Fuel Systems) ¼ RH SIDE 8) Install fuel injector. EN0810 EN0808 9) Tighten bolt which install fuel injector pipe onto intake manifold. Tightening torque: 19 N·m (1.94 kgf-m, 14.0 ft-lb) ¼ LH SIDE EN0809 10) Tighten two bolts which install fuel pipes on the left side of intake manifold.
  • Page 27 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 11) Connect evaporation hoses to purge valve. 13) Install purge control solenoid valve. CAUTION: Tightening torque: Carefully connect the evaporation hoses. 16 N·m (0.16 kgf-m, 1.2 ft-lb) EN0802 14) Connect hoses to purge control solenoid valve.
  • Page 28 INTAKE MANIFOLD Fuel Injection (Fuel Systems) 16) Connect connector to tumble generator valve 19) Install throttle body to intake manifold. sensor. NOTE: Replace gasket with a new one. Tightening torque: 22 N·m (2.2 kgf-m, 16 ft-lb) EN0800 17) Connect connector to tumble generator valve actuator.
  • Page 29 INTAKE MANIFOLD Fuel Injection (Fuel Systems) EN0796 23) Install fuel pipe protector. Tightening torque: 19 N·m (1.94 kgf-m, 14.0 ft-lb) EN0794 E: INSPECTION S185034A10 Make sure the fuel pipe and fuel hoses are not cracked and that connections are tight. FU(DOHC TURBO)-28...
  • Page 30: Engine Coolant Temperature Sensor

    ENGINE COOLANT TEMPERATURE SENSOR Fuel Injection (Fuel Systems) 4. Engine Coolant Temperature Sensor S185047 A: REMOVAL S185047A18 1) Disconnect battery ground cable. G6M0095 2) Remove the generator <Ref. to SC-12, REMOVAL, Generator.> 3) Disconnect connector from engine coolant tem- perature sensor. EN0851 4) Remove engine coolant temperature sensor.
  • Page 31: Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR Fuel Injection (Fuel Systems) 5. Crankshaft Position Sensor B: INSTALLATION S185043A11 Install in the reverse order of removal. S185043 A: REMOVAL Tightening torque: S185043A18 T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect battery ground cable. B2M1252B G6M0095 2) Remove bolt which install crankshaft position sensor to cylinder block.
  • Page 32: Camshaft Position Sensor

    CAMSHAFT POSITION SENSOR Fuel Injection (Fuel Systems) 6. Camshaft Position Sensor B: INSTALLATION S185041A11 Install in the reverse order of removal. S185041 A: REMOVAL Tightening torque: S185041A18 T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect battery ground cable. G2M0417 G6M0095 2) Disconnect connector from camshaft position sensor.
  • Page 33: Knock Sensor

    KNOCK SENSOR Fuel Injection (Fuel Systems) 7. Knock Sensor B: INSTALLATION S185042A11 S185042 1) Install knock sensor to cylinder block. A: REMOVAL S185042A18 Tightening torque: 1) Disconnect battery ground cable from battery 24 N·m (2.4 kgf-m, 17.4 ft-lb) ground terminal. NOTE: The extraction area of the knock sensor cord must be positioned at a 60°...
  • Page 34: Throttle Position Sensor

    THROTTLE POSITION SENSOR Fuel Injection (Fuel Systems) 8. Throttle Position Sensor B: INSTALLATION S185039A11 S185039 Install in the reverse order of removal. A: REMOVAL S185039A18 Tightening torque: 1) Disconnect battery ground cable. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) G6M0095 EN0820 2) Remove inter cooler.
  • Page 35: Mass Air Flow And Intake Air Temperature Sensor

    MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR Fuel Injection (Fuel Systems) 9. Mass Air Flow and Intake Air Temperature Sensor S185770 A: REMOVAL S185770A18 1) Disconnect battery ground cable. G6M0095 2) Disconnect connector mass air flow and intake air temperature sensor. 3) Remove mass air flow and intake air tempera- ture sensor.
  • Page 36: Pressure Sensor

    PRESSURE SENSOR Fuel Injection (Fuel Systems) 10. Pressure Sensor S185765 A: REMOVAL S185765A18 1) Disconnect battery ground cable. G6M0095 2) Remove idle air control solenoid valve. <Ref. to FU(SOHC)-38, REMOVAL, Idle Air Control Sole- noid Valve.> 3) Disconnect connectors from pressure sensor. EN0821 4) Remove pressure sensor from throttle body.
  • Page 37: Idle Air Control Solenoid Valve

    IDLE AIR CONTROL SOLENOID VALVE Fuel Injection (Fuel Systems) 11. Idle Air Control Solenoid B: INSTALLATION S185056A11 Valve Install in the reverse order of removal. S185056 NOTE: A: REMOVAL S185056A18 Always use new gasket. 1) Disconnect battery ground cable. Tightening torque: 2.8 N·m (0.29 kgf-m, 2.1 ft-lb) G6M0095 EN0823...
  • Page 38: Fuel Injector

    FUEL INJECTOR Fuel Injection (Fuel Systems) 12. Fuel Injector 4) Remove bolts which hold injector pipe to intake S185051 manifold. A: REMOVAL S185051A18 1. RH SIDE S185051A1801 1) Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 2) Remove fuel pipe protector. EN0808 EN0794 3) Disconnect connector from fuel injector.
  • Page 39 FUEL INJECTOR Fuel Injection (Fuel Systems) 2. LH SIDE 4) Remove fuel injector while lifting up fuel injec- S185051A1802 tor pipe. 1) Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 2) Disconnect connector from fuel injector. EN0824 B: INSTALLATION EN0798 S185051A11 1.
  • Page 40 FUEL INJECTOR Fuel Injection (Fuel Systems) Tightening torque: Tightening torque: 5 N·m (0.51 kgf-m, 3.69 ft-lb) 19 N·m (1.94 kgf-m, 14.0 ft-lb) EN0805 EN0809 Tightening torque: Tightening torque: 19 N·m (1.94 kgf-m, 14.0 ft-lb) 19 N·m (1.94 kgf-m, 14.0 ft-lb) EN0806 EN0794 Tightening torque:...
  • Page 41: Tumble Generator Valve Assembly

    TUMBLE GENERATOR VALVE ASSEMBLY Fuel Injection (Fuel Systems) 13. Tumble Generator Valve 6) Remove tumble generator valve body from intake manifold. Assembly S185766 A: REMOVAL S185766A18 1) Disconnect battery ground cable. EN0815 B: INSTALLATION S185766A11 Install in the reverse order of removal. G6M0095 NOTE: 2) Remove intake manifold.
  • Page 42: Wastegate Control Solenoid Valve

    WASTEGATE CONTROL SOLENOID VALVE Fuel Injection (Fuel Systems) 14. Wastegate Control Solenoid Valve S185057 A: REMOVAL S185057A18 1) Disconnect battery ground cable. G6M0095 2) Disconnect connector (A) from wastegate con- trol solenoid valve. 3) Disconnect pressure hoses (B) from wastegate control solenoid valve.
  • Page 43: Front Oxygen (A/F) Sensor

    S185642 A: REMOVAL S185642A18 1) Disconnect battery ground cable. EN0832 7) Apply SUBARU CRC or its equivalent to threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. G6M0095 SUBARU CRC (Part No. 004301003) 2) Disconnect connector from front oxygen (A/F) 8) Remove front oxygen (A/F) sensor.
  • Page 44 FRONT OXYGEN (A/F) SENSOR Fuel Injection (Fuel Systems) 7) Connect connector of front oxygen (A/F) sen- B: INSTALLATION S185642A11 sor. 1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to threaded por- tion of front oxygen (A/F) sensor to make the next removal easier.
  • Page 45: Rear Oxygen Sensor

    EN0834 4) Vertically draw out clip (A) from crossmember (B). S2M2254 5) Apply SUBARU CRC or its equivalent to threaded portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) FU(DOHC TURBO)-44...
  • Page 46 REAR OXYGEN SENSOR Fuel Injection (Fuel Systems) 6) Connect battery ground cable. B: INSTALLATION S185657A11 1) Before installing rear oxygen sensor, apply anti- seize compound only to threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to protector of rear oxygen sensor.
  • Page 47: Exhaust Temperature Sensor

    <Ref. EX(DOHC TURBO)-13, REMOVAL, Joint Pipe.> 3) Apply SUBARU CRC or its equivalent to threaded portion of exhaust temperature sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 4) Remove exhaust temperature sensor.
  • Page 48: Engine Control Module

    ENGINE CONTROL MODULE Fuel Injection (Fuel Systems) 18. Engine Control Module S185049 A: REMOVAL S185049A18 1) Disconnect battery ground cable. G6M0095 2) Remove lower inner trim of passenger side. <Ref. to EI-38, REMOVAL, Lower Inner Trim.> 3) Detach floor mat of front passenger seat. 4) Remove protect cover.
  • Page 49: Main Relay

    MAIN RELAY Fuel Injection (Fuel Systems) 19. Main Relay 4) Remove main relay from mounting bracket. S185050 A: REMOVAL S185050A18 1) Disconnect battery ground cable. S2M0137 B: INSTALLATION S185050A11 G6M0095 Install in the reverse order of removal. 2) Remove bolt which holds bracket of main relay and fuel pump relay.
  • Page 50: Fuel Pump Relay

    FUEL PUMP RELAY Fuel Injection (Fuel Systems) 20. Fuel Pump Relay S185048 A: REMOVAL S185048A18 1) Disconnect battery ground cable. G6M0095 2) Disconnect connector from fuel pump relay. S2M0093 3) Remove fuel pump relay from mounting bracket. S2M0138 B: INSTALLATION S185048A11 Install in the reverse order of removal.
  • Page 51: Fuel

    FUEL Fuel Injection (Fuel Systems) 21. Fuel 3) Disconnect battery ground cable. S185052 A: OPERATION S185052A16 1. RELEASING OF FUEL PRESSURE S185052A1601 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Disconnect ground terminal from battery. 1) Disconnect connector from fuel pump relay. G6M0095 4) Remove the floor box located just behind the rear seats.
  • Page 52 FUEL Fuel Injection (Fuel Systems) 8) Move clips, and then disconnect fuel return 12) Remove service hole cover. hose (B) and jet pump hose (C). G2M0863 S2M0060A 13) Disconnect connector from fuel sub level sen- 9) Remove nuts which install fuel pump assembly sor.
  • Page 53 FUEL Fuel Injection (Fuel Systems) 17) Drain fuel from there. WARNING: Do not use a motor pump when draining fuel. S2M0247 FU(DOHC TURBO)-52...
  • Page 54: Fuel Tank

    FUEL TANK Fuel Injection (Fuel Systems) 22. Fuel Tank 8) Disconnect two-way valve hose (A) from two- S185053 way valve and disconnect canister hose (B) from A: REMOVAL canister. S185053A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼...
  • Page 55 FUEL TANK Fuel Injection (Fuel Systems) 12) Support fuel tank with transmission jack, 4) Connect fuel filler hose (A) and air vent hose remove bolts from bands and dismount fuel tank (B). from the vehicle. WARNING: A helper is required to perform this work. EN0539 5) Connect fuel hoses, and hold then with clips and quick connector.
  • Page 56 FUEL TANK Fuel Injection (Fuel Systems) 8) Connect connectors to fuel tank cord and plug service hole with grommet. S2M0164 9) Set rear seat and floor mat. 10) Connect connector to fuel pump relay. S2M0093 C: INSPECTION S185053A10 1) Make sure there are no cracks, holes, or other damage on the fuel tank.
  • Page 57: Fuel Filler Pipe

    FUEL FILLER PIPE Fuel Injection (Fuel Systems) 23. Fuel Filler Pipe 8) Remove fuel filler pipe protector. S185022 A: REMOVAL S185022A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Release fuel pressure.
  • Page 58 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 12) Loosen clamp and separate fuel filler hose (A) 3) Align holes in fuel filler pipe neck and set cup from fuel filler pipe. (B), and tighten screws. 13) Move clip and separate air vent hose (B). NOTE: If edges of rubber packing are folded toward the inside, straighten it with a screwdriver.
  • Page 59 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 6) Insert fuel filler hose (A) approximately 35 to 40 9) Tighten bolts which hold evaporation hoses mm (1.38 to 1.57 in) over the lower end of fuel filler onto clip of fuel filler pipe. pipe and tighten clamp.
  • Page 60 FUEL FILLER PIPE Fuel Injection (Fuel Systems) 15) Connect battery ground terminal. G6M0095 FU(DOHC TURBO)-59...
  • Page 61: Fuel Pump

    FUEL PUMP Fuel Injection (Fuel Systems) 24. Fuel Pump 6) Disconnect connector from fuel pump. S185025 A: REMOVAL S185025A18 WARNING: ¼ Place “No fire” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>...
  • Page 62 FUEL PUMP Fuel Injection (Fuel Systems) B: INSTALLATION S185025A11 Install in the reverse order of removal. Do the fol- lowing: (1) Always use new gaskets. (2) Ensure sealing portion is free from fuel or for- eign particles before installation. (3) Tighten nuts in alphabetical sequence shown in the figure to specified torque.
  • Page 63: Fuel Level Sensor

    FUEL LEVEL SENSOR Fuel Injection (Fuel Systems) 25. Fuel Level Sensor S185026 A: REMOVAL S185026A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. NOTE: Fuel level sensor is built in fuel pump assembly. 1) Remove fuel pump...
  • Page 64: Fuel Sub Level Sensor

    FUEL SUB LEVEL SENSOR Fuel Injection (Fuel Systems) 26. Fuel Sub Level Sensor 6) Remove bolts which install fuel sub level sensor S185023 on fuel tank. A: REMOVAL S185023A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Disconnect battery ground cable.
  • Page 65: 27. Fuel Filter

    FUEL FILTER Fuel Injection (Fuel Systems) 27. Fuel Filter S185027 A: REMOVAL S185027A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>...
  • Page 66: Fuel Cut Valve

    FUEL CUT VALVE Fuel Injection (Fuel Systems) 28. Fuel Cut Valve S185021 A: REMOVAL S185021A18 WARNING: ¼ Place “NO FIRE” signs near the working area. ¼ Be careful not to spill fuel on the floor. 1) Remove fuel tank. <Ref. FU(DOHC TURBO)-53, REMOVAL, Fuel Tank.>...
  • Page 67: Fuel Damper Valve

    FUEL DAMPER VALVE Fuel Injection (Fuel Systems) 29. Fuel Damper Valve S185708 A: REMOVAL S185708A18 1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Remove fuel damper valve from fuel return line. EN0852 B: INSTALLATION S185708A11 Install in the reverse order of removal.
  • Page 68: Fuel Delivery, Return And Evaporation Lines

    FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 30. Fuel Delivery, Return and 3) Open fuel filler flap lid and remove fuel filler cap. Evaporation Lines S185019 4) Remove floor mat. <Ref. to EI-43, REMOVAL, Floor Mat.> A: REMOVAL S185019A18 5) Remove fuel delivery pipes and hoses, fuel 1) Set vehicle on the lift.
  • Page 69 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 9) Separate quick connector on fuel delivery and return line. (1) Clean pipe and connector, if they are cov- ered with dust. (2) Hold connector (A) and push retainer (B) down.
  • Page 70 FUEL DELIVERY, RETURN AND EVAPORATION LINES Fuel Injection (Fuel Systems) 2) Connect fuel delivery hose to pipe with an over- lap of 20 to 25 mm (0.79 to 0.98 in). Type A: When fitting length is specified. Type B: When fitting length is not specified. : 2.5±1.5 mm (0.098±0.059 in) L: 22.5±2.5 mm (0.886±0.098 in) B2M1194B...
  • Page 71: Fuel System Trouble In General

    FUEL SYSTEM TROUBLE IN GENERAL Fuel Injection (Fuel Systems) 31. Fuel System Trouble in General S185571 A: INSPECTION S185571A10 Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten Defective terminal contact.

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