Subaru IMPREZA 2001 Service Manual
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Subaru IMPREZA 2001 Service Manual

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2001 IMPREZA SERVICE MANUAL
ENGINE 2 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, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance 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 genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FUEL INJECTION (FUEL SYSTEMS)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
EXHAUST
IGNITION
ENGINE(DIAGNOSTICS)
FUEL INJECTION (FUEL SYSTEMS)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
IGNITION
ENGINE (DIAGNOSTICS)
FU(SOHCw/oOBD)
EC(SOHCw/oOBD)
EX(SOHCw/oOBD)
IG(SOHCw/oOBD)
EN(SOHCw/oOBD)
FU(DOHC TURBO)
EC(DOHC TURBO)
IN(DOHC TURBO)
ME(DOHC TURBO)
EX(DOHC TURBO)
IG(DOHC TURBO)
EN(DOHC TURBO)
G1830GE3

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  • Page 1 (AUX. EMISSION CONTROL DEVICES) EXHAUST EX(SOHCw/oOBD) IGNITION IG(SOHCw/oOBD) This service manual has been prepared to provide SUBARU service personnel ENGINE(DIAGNOSTICS) EN(SOHCw/oOBD) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. FUEL INJECTION (FUEL SYSTEMS)

  • 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............27 Crankshaft Position Sensor...............28 Camshaft Position Sensor.................29 Knock Sensor....................30 Throttle Position Sensor................31 Mass Air Flow and Intake Air Temperature Sensor ........32 Pressure Sensor ..................33 Idle Air Control Solenoid Valve ..............34 Fuel Injector ....................35 Tumble Generator Valve Assembly ............38...

  • Page 3: General Description

    GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model 60 2 (15.9 US gal, 13.2 Imp gal) Capacity 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) FU(DOHC TURBO)-3...

  • Page 5: Intake Manifold

    GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (19) (18) (22) (17) (20) (24) (16) (23) (21) (14) (26) (15) (26) (12) (13) (25) (12) (11) (11) (10) (16) (10) (14) (15) EN0778 FU(DOHC TURBO)-4...
  • Page 6 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Fuel pipe ASSY (13) Accelerator cable bracket (25) Fuel pipe protector LH Fuel hose (14) Fuel injector (26) Nipple Clip (15) Insulator Purge control solenoid valve (16) Fuel injector pipe Tightening torque: N·m (kgf-m, ft-lb) Vacuum hose (17) Pressure regulator...

  • Page 7: Air Intake System

    GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM EN0779 Gasket Pressure sensor Tightening torque: N·m (kgf-m, ft-lb) Throttle position sensor T1: 1.6 (0.16, 1.2) Idle air control solenoid valve T2: 2.8 (0.29, 2.1) Throttle body T3: 22 (2.2, 16) FU(DOHC TURBO)-6...
  • Page 8 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS EN0780 Crankshaft position sensor Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) Knock sensor T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.4) FU(DOHC TURBO)-7...
  • Page 9 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK (30) (17) (10) (11) (12) (12) (12) (15) (14) (29) (29) (13) (12) (12) (28) (16) (12) (12) (18) (21) (20) (22) (19) (27) (12) (12) (26) (23) (12) (24) (20) (12) (25) EN0998...
  • Page 10 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat sealed cover (13) Evaporation hose B (25) Fuel return hose B Fuel tank band (14) Joint pipe (26) Fuel sub meter gasket Protector LH (15) Evaporation hose C (27) Jet pump filter Protector RH (16) Evaporation pipe ASSY (28)
  • Page 11 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (19) (18) (17) (24) (20) (16) (25) (15) (24) (22) (13) (21) (23) (14) (12) (1) (1) (10) (10) (11) EN0440 FU(DOHC TURBO)-10...
  • Page 12 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A Fuel delivery hose A (12) Grommet (22) Connector Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B Fuel filter holder (14) Canister (24)
  • Page 13 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE (10) (11) EN0441 Fuel filter pipe ASSY Air vent pipe Tightening torque: N·m (kgf-m, ft-lb) Evaporation hose holder Air vent pipe holder T: 7.5 (0.76, 5.5) Clamp Filler pipe packing Clamp Filler ring Air vent hose...
  • Page 14 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) C: CAUTION • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Wear working clothing, including a cap, protec- • 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 B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect battery ground cable. Replace gasket with a new one. Tightening torque: 22 N·m (2.2 kgf-m, 15.9 ft-lb) G6M0095 2) Remove intercooler.

  • Page 16: Intake Manifold

    INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold (2) Disconnect the power steering switch con- nector. A: REMOVAL 1) Release fuel pressure. <Ref. to FU(DOHC TUR- BO)-49, RELEASING OF FUEL PRESSURE, OP- ERATION, Fuel.> 2) Remove under cover. 3) Drain coolant about 3.0 2 (3.2 US qt, 2.6 Imp qt).
  • Page 17 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (6) Place power steering pump on the right side 14) Disconnect Pressure hose from intake duct. wheel apron. EN0787 15) Disconnect engine harness connectors from EN0208 10) Disconnect emission hose from PCV valve. bulkhead harness connectors, and remove engine harness connectors from bracket.
  • Page 18 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 18) Disconnect connector from camshaft position B: INSTALLATION sensor. 1) Install intake manifold onto cylinder heads. CAUTION: Always use new gaskets. Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb) B2M1251 19) Disconnect fuel delivery hose, return hose and evaporation hose.
  • Page 19 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 5) Connect connector to camshaft position sensor. 9) Connect emission hose to PCV valve. EN0789 B2M1251 6) Connect engine harness connector to bulkhead 10) Connect pressure hose to intake duct. harness connectors, and install engine harness connector to bracket.
  • Page 20 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (3) Install power steering pump on bracket, and 17) Connect connector to fuel pump relay. tighten bolts. Tightening torque: 20.1 N·m (2.05 kgf-m, 14.8 ft-lb) EN0344 18) Install battery and connect battery cables. H2M1954 (4) Install power steering pipe brackets on right side intake manifold.
  • Page 21 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) C: DISASSEMBLY 4) Disconnect connector from throttle position sen- sor (A), idle air control solenoid valve (B) and pres- 1) Remove fuel pipe protector LH. sure sensor (C). EN0793 EN0797 2) Remove fuel pipe protector RH. 5) Remove throttle body from intake manifold.
  • Page 22 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 8) Disconnect connector from tumble generator 12) Disconnect evaporation hoses from purge valve sensor. valve. EN0800 EN0804 9) Disconnect connector from purge control sole- 13) Remove two bolts which hold fuel pipes on the noid valve.
  • Page 23 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) • 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 24 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) D: ASSEMBLY 5) Connect left side fuel hose to injector pipe, and tighten clamp screw. 1) Install tumble generator valve assembly to intake manifold. Tightening torque: 8.25 N·m (0.84 kgf-m, 6.08 ft-lb) EN0812 6) Install engine harness to intake manifold. 7) Install harness bracket which hold engine har- ness onto intake manifold.
  • Page 25 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 9) Tighten bolt which install fuel injector pipe onto 10) Tighten two bolts which install fuel pipes on the intake manifold. left side of intake manifold. Tightening torque: Tightening torque: 19 N·m (1.94 kgf-m, 14.0 ft-lb) 5 N·m (0.51 kgf-m, 3.69 ft-lb) •...
  • Page 26 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 12) Connect evaporation hose to intake manifold. 16) Connect connector to tumble generator valve sensor. EN0803 13) Install purge control solenoid valve. EN0800 17) Connect connector to tumble generator valve Tightening torque: actuator. 16 N·m (0.16 kgf-m, 1.2 ft-lb) EN0799 EN0802 18) Connect connector to fuel injector.
  • Page 27 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 20) Connect connector to throttle position sensor 23) Install fuel pipe protector LH. (A), idle air control solenoid valve (B) and pressure Tightening torque: sensor (C). 19 N·m (1.94 kgf-m, 19.0 ft-lb) EN0797 EN0793 21) Install engine ground terminal to intake mani- fold.

  • Page 28: Engine Coolant Temperature Sensor

    ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature B: INSTALLATION Install in the reverse order of removal. Sensor Tightening torque: A: REMOVAL 16 N·m (0.16 kgf-m, 1.2 ft-lb) 1) Disconnect battery ground cable. G6M0095 2) Remove the generator <Ref. to SC-12, REMOV- AL, Generator.>...

  • Page 29: Crankshaft Position Sensor

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

  • Page 30: Camshaft Position Sensor

    CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect battery ground cable. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) G6M0095 G2M0417 2) Disconnect connector from camshaft position sensor.

  • Page 31: Knock Sensor

    KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install knock sensor to cylinder block. A: REMOVAL 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 45°...

  • Page 32: Throttle Position Sensor

    THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect battery ground cable. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing throttle position sensor, adjust to the specified data.

  • Page 33: 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 B: INSTALLATION Install in the reverse order of removal. Temperature Sensor Tightening torque: A: REMOVAL 7.5 N·m (0.76 kgf-m, 5.5 ft-lb) 1) Disconnect battery ground cable.

  • Page 34: Pressure Sensor

    PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 10.Pressure Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect battery ground cable. Replace gaskets for pressure sensor and idle air control solenoid valve with new ones. Tightening torque: 2.8 N·m (0.29 kgf-m, 2.1 ft-lb) G6M0095 2) Remove idle air control solenoid valve.

  • Page 35: Idle Air Control Solenoid Valve

    IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 11.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve CAUTION: A: REMOVAL Always use new gasket. 1) Disconnect battery ground cable. Tightening torque: 2.8 N·m (0.29 kgf-m, 2.1 ft-lb) G6M0095 2) Disconnect connector from idle air control sole- EN0823...

  • Page 36: Fuel Injector

    FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 12.Fuel Injector 5) Remove fuel injector while lifting up fuel injector pipe. A: REMOVAL 1. RH SIDE 1) Remode intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 2) Remove fuel pipe protector RH. EN0810 2.
  • Page 37 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 4) Remove bolts which hold injector pipe to intake B: INSTALLATION manifold. 1. RH SIDE Install in the reverse order of removal. NOTE: Replace O-ring and insulators with new ones. EN0805 EN0825 (A) O-ring (B) Fuel injector (C) Insulator Tightening torque:...
  • Page 38 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 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) EN0794 EN0806 Tightening torque: 2. LH SIDE 19 N·m (1.94 kgf-m, 14.0 ft-lb) Install in the reverse order of removal. NOTE: Replace O-ring and insulators with new ones.

  • Page 39: Tumble Generator Valve Assembly

    TUMBLE GENERATOR VALVE ASSEMBLY FUEL INJECTION (FUEL SYSTEMS) 13.Tumble Generator Valve As- 6) Remove tumble generator valve body from in- take manifold. sembly A: REMOVAL 1) Disconnect battery ground cable. EN0815 G6M0095 2) Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 3) Disconnect connector from tumble generator valve sensor.
  • Page 40 TUMBLE GENERATOR VALVE ASSEMBLY FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Install in the reverse order of removal. NOTE: Always use new gaskets. Tightening torque: 8.25 N·m (0.84 kgf-m, 6.1 ft-lb) EN0815 FU(DOHC TURBO)-39...

  • Page 41: Wastegate Control Solenoid Valve

    WASTEGATE CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 14.Wastegate Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve Tightening torque: A: REMOVAL 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect battery ground cable. EN0830 G6M0095 2) Remove solenoid valve cover. EN0828 3) Disconnect connector (A) from wastegate con- trol solenoid valve.

  • Page 42: Front Oxygen (A/F) Sensor

    4) Remove front right side wheel. 5) Lift-up the vehicle. 6) Remove service hole cover. EN0832 7) Apply SUBARU CRC or its equivalent to thread- ed portion of front oxygen (A/F) sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003)
  • Page 43 FRONT OXYGEN (A/F) SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 7) Install solenoid valve cover. 1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to threaded portion of front oxygen (A/F) sensor to make the next removal easier. Anti-seize compound: SS-30 by JET LUBE CAUTION:...

  • Page 44: Rear Oxygen Sensor

    3) Disconnect connector from rear oxygen sensor. EN0835 3) Connect connector to rear oxygen sensor. EN0834 4) Apply SUBARU CRC or its equivalent to thread- ed portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove rear oxygen sensor.

  • Page 45: Exhaust Temperature Sensor

    G6M0095 2) Remove joint pipe. <Ref. to EX(DOHC TURBO)- 12, REMOVAL, Joint Pipe.> 3) Apply SUBARU CRC or its equivalent to thread- ed portion of exhaust temperature sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 4) Remove exhaust temperature.

  • Page 46: Engine Control Module

    ENGINE CONTROL MODULE FUEL INJECTION (FUEL SYSTEMS) 18.Engine Control Module A: REMOVAL 1) Disconnect battery ground cable. G6M0095 2) Remove lower inner trim of passenger side. <Ref. to EI-29, REMOVAL, Lower Inner Trim.> 3) Detach floor mat of front passenger seat. 4) Remove protect cover.

  • Page 47: Main Relay

    MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 19.Main Relay A: REMOVAL 1) Disconnect battery ground cable. G6M0095 2) Remove passenger’s side front side sill cover. 3) Remove bolt which holds main relay bracket on body. 4) Disconnect connectors from main relay. EN0534 B: INSTALLATION Install in the reverse order of removal.

  • Page 48: Fuel Pump Relay

    FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Pump Relay A: REMOVAL 1) Disconnect battery ground cable. G6M0095 2) Remove passenger’s side front side sill cover. 3) Remove bolt which holds fuel pump relay brack- et on body. 4) Disconnect connector from fuel pump relay. EN0535 5) Remove fuel pump relay from mounting bracket.

  • Page 49: Fuel Pump Controller

    FUEL PUMP CONTROLLER FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Pump Controller A: REMOVAL 1) Disconnect battery ground cable. G6M0095 2) Remove rear quarter Trim. <Ref. to EI-30, RE- MOVAL, Rear Quarter Trim.> 3) Disconnect connector from fuel pump control unit. EN0837 4) Remove fuel pump control unit.

  • Page 50: Fuel

    FUEL FUEL INJECTION (FUEL SYSTEMS) 22.Fuel 3) Lift-up the vehicle. 4) Drain fuel from fuel tank. A: OPERATION Set a container under the vehicle and remove drain plug from fuel tank. 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. •...

  • Page 51: Fuel Tank

    FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Tank 9) Loosen clamp and disconnect fuel filler hose (A) and air vent hose (B) from fuel filler pipe. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Set vehicle on the lift.
  • Page 52 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 2) Set fuel tank and temporarily tighten bolts of fuel 6) Tighten band mounting bolts. tank bands. Tightening torque: WARNING: 33 N·m (3.4 kgf-m, 25 ft-lb) A helper is required to perform this work. EN0541 EN0541 7) Install rear crossmember.

  • Page 53: Fuel Filler Pipe

    FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Filler Pipe 8) Drain fuel from fuel tank. Set a container under the vehicle and remove drain plug from fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. •...
  • Page 54 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 12) Deisconnect air vent hose from fuel filler pipe. B: INSTALLATION 1) Hold fuel filler flap open. 2) Set fuel saucer (A) with rubber packing (C) and insert fuel filler pipe into hole from the inner side of apron.
  • Page 55 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 6) Insert fuel filler hose (A) approximately 35 to 40 9) Tighten bolts which hold evaporation hoses onto mm (1.38 to 1.57 in) over the lower end of fuel filler clip of fuel filler pipe. pipe and tighten clamp.
  • Page 56 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 15) Connect battery ground terminal. G6M0095 FU(DOHC TURBO)-55...

  • Page 57: Fuel Pump

    FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Pump 8) Remove access hole lid. 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.
  • Page 58 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 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 figure to specified torque.

  • Page 59: Fuel Level Sensor

    FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 26.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 fuel pump assembly.

  • Page 60: Fuel Sub Level Sensor

    FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Sub Level Sensor 6) Remove service hole cover. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Disconnect battery ground cable. G2M0863 7) Disconnect connector from fuel sub meter.
  • Page 61 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) B2M3178 FU(DOHC TURBO)-60...

  • Page 62: Fuel Filter

    FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 28.Fuel Filter A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(DOHC TUR- BO)-49, RELEASING OF FUEL PRESSURE, OP- ERATION, Fuel.>...

  • Page 63: Fuel Cut Valve

    FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 29.Fuel Cut Valve A: REMOVAL 1) Remove fuel tank. <Ref. to FU(DOHC TURBO)- 50, REMOVAL, Fuel Tank.> 2) Move clip and disconnect evaporation hose from fuel cut valve. S2M0176 3) Remove bolts which install fuel cut valve. B: INSTALLATION Install in the reverse order of removal.

  • Page 64: Fuel Damper Valve

    FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 30.Fuel Damper Valve A: REMOVAL 1) Release fuel pressure. <Ref. to FU(DOHC TUR- BO)-49, RELEASING OF FUEL PRESSURE, OP- ERATION, Fuel.> 2) Remove fuel damper valve from fuel return line. EN0852 B: INSTALLATION Install in the reverse order of removal.

  • Page 65: Fuel Delivery, Return And Evaporation Lines

    FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 31.Fuel Delivery, Return and 3) Open fuel filler flap lid and remove fuel filler cap. 4) Remove floor mat. <Ref. to EI-37, REMOVAL, Evaporation Lines Floor Mat.> 5) Remove fuel delivery pipes and hoses, fuel re- A: REMOVAL turn pipes and hoses, evaporation pipes and hos- 1) Set vehicle on the lift.
  • Page 66 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 9) Separate quick connector on fuel delivery and (1) Set new retainer (B) to connector (A). return line. (2) Push pipe into connector completely. (1) Clean pipe and connector, if they are cov- NOTE: ered with dust.
  • Page 67 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 : 2.5 ±...

  • Page 68: Fuel System Trouble In General

    FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) 32.Fuel System Trouble in Gen- eral A: INSPECTION 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.
  • Page 69 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) FU(DOHC TURBO)-68...

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