FUEL INJECTION (FUEL SYSTEMS)(H4DO)
FU(H4DO)
  1. General Description
  2. Throttle Body
  3. Intake Manifold Assembly
  4. Tumble Generator Valve
  5. Tumble Generator Valve Actuator
  6. Fuel Insulator
  7. Fuel Injector
  8. Fuel Pressure Sensor
  9. High Pressure Fuel Pump
  10. High Pressure Fuel Delivery Pipe
  11. Engine Wiring Harness
  12. Engine Coolant Temperature Sensor
  13. Engine Oil Temperature Sensor
  14. Crankshaft Position Sensor
  15. Crankshaft Position Sensor Plate
  16. Camshaft Position Sensor
  17. Oil Control Solenoid
  18. Knock Sensor
  19. Throttle Position Sensor
  20. Mass Air Flow and Intake Air Temperature Sensor
  21. Manifold Absolute Pressure Sensor
  22. Front Oxygen (A/F) Sensor
  23. Rear Oxygen Sensor
  24. SI-DRIVE (SUBARU Intelligent Drive) Selector
  25. Engine Control Module (ECM)
  26. Main Relay
  27. Fuel Pump Relay
  28. Fuel
  29. Fuel Tank Protector
  30. Fuel Tank
  31. Fuel Filler Pipe
  32. Fuel Pump
  33. Fuel Level Sensor
  34. Fuel Sub Level Sensor
  35. Fuel Filter
  36. Fuel Delivery and Evaporation Lines
  37. Symptoms and causes
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > General Description　
SPECIFICATION

Fuel tank

Capacity

63 L (16.6 US gal, 13.9 Imp gal)

Location

Under rear seat

Fuel pump

Type

Impeller

Shutoff discharge pressure

900 kPa (9.18 kg/cm2, 130.5psi) or less

Discharge rate

102 L (26.9 US gal, 22.4 Imp gal)/h or more

[12.5 V at 400 kPa (4.1 kg/cm2, 58.0psi)]

Fuel filter

In-tank type
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > General Description　
COMPONENT
1. INTAKE MANIFOLD ASSEMBLY

(1)

Intake manifold ASSY

(5)

Collector cover bracket

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Gasket

(6)

Cushion

T1:

3.4 (0.3, 2.5)

(3)

Manifold absolute pressure sensor

T2:

6.4 (0.7, 4.7)

(4)

O-ring

T3:

25 (2.5, 18.4)
2. FUEL INJECTOR

(1)

Fuel pressure sensor

(7)

Fuel injector

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Fuel injector pipe RH

(8)

Slider washer

T1:

19 (1.9, 14.0)

(3)

Fuel injector holder

(9)

C-ring

T2:

46 (4.7, 33.9)

(4)

Stopper ring

(10)

Fuel injector seal

(5)

O-ring seal

(11)

Fuel injector pipe LH

(6)

Back-up ring

(12)

Coupling harness

∗ When removing the fuel pressure sensor from the fuel injector pipe RH, replace it with a new one.
3. FUEL PIPE

(1)

Purge control solenoid valve

(10)

High-pressure fuel delivery pipe ASSY

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Purge control solenoid valve bracket

(11)

High-pressure fuel pump

T1:

6.4 (0.7, 4.7)

(3)

Vacuum hose

(12)

O-ring

T2:

12 (1.2, 8.9)

(4)

Fuel pipe

(13)

Gasket

T3:

19 (1.9, 14.0)

(5)

Fuel delivery pipe A

(14)

Fuel delivery pipe B

T4:

21 (2.1, 15.5)

(6)

Fuel pipe protector

(15)

High-pressure fuel delivery pipe

T5:

48 (4.9, 35.4)

(7)

Fuel pipe insulator No. 1

(16)

Fuel pump lifter

T6:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION

(8)

Fuel pipe insulator No. 2

(17)

High-pressure fuel pump case

(9)

Fuel pipe insulator No. 3
4. THROTTLE BODY

(1)

Gasket

(2)

Throttle body

Tightening torque: N·m (kgf-m, ft-lb)

T:

8 (0.8, 5.9)
5. CRANKSHAFT POSITION SENSOR, CAMSHAFT POSITION SENSOR, KNOCK SENSOR AND OIL CONTROL SOLENOID

(1)

Camshaft position sensor

(5)

Oil control solenoid

Tightening torque: N·m (kgf-m, ft-lb)

(2)

O-ring

(6)

Back-up ring

T1:

6.4 (0.7, 4.7)

(3)

Knock sensor

(7)

O-ring

T2:

24 (2.4, 17.7)

(4)

Crankshaft position sensor

(8)

Coupling harness
6. FUEL TANK 1

(1)

Fuel delivery tube

(9)

Fuel tank

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Ring nut

(10)

Cushion

T1:

2 (0.2, 1.5)

(3)

Ring nut plate

(11)

Cushion

T2:

2.5 (0.3, 1.8)

(4)

Fuel pump ASSY

(12)

Clamp

T3:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump>INSTALLATION

(5)

Fuel sub level sensor

(13)

Fuel filler hose

T4:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Sub Level Sensor>INSTALLATION

(6)

Fuel sub delivery tube

(14)

Clamp

(7)

Filter

(15)

Circulate tube

(8)

Gasket

7. FUEL TANK 2

(1)

Fuel tank band RH

(4)

Fuel tank protector LH

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Fuel tank band LH

(5)

Clip

T1:

18 (1.8, 13.3)

(3)

Fuel tank protector RH

T2:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Tank>INSTALLATION
8. FUEL LINE 1

(1)

Purge hose

(9)

Fuel pipe ASSY

(17)

Pipe clamp

(2)

Clip

(10)

Fuel pipe bracket C

(18)

Pipe clamp

(3)

Clip

(11)

Purge tube

(19)

Pipe clamp

(4)

Fuel delivery tube clamp

(12)

Purge tube

(5)

Fuel delivery tube

(13)

Pipe clamp

Tightening torque: N·m (kgf-m, ft-lb)

(6)

Fuel delivery tube clamp

(14)

Pipe clamp

T:

18 (1.8, 13.3)

(7)

Fuel pipe bracket A

(15)

Pipe clamp

(8)

Fuel pipe bracket B

(16)

Pipe clamp
9. FUEL LINE 2

(1)

Leak check valve ASSY

(4)

Canister

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Drain tube

(5)

Canister bracket

T:

8 (0.8, 5.9)

(3)

Leak check valve ASSY bracket
10. FUEL FILLER PIPE

(1)

Fuel filler cap

(7)

Drain filter

(12)

Upper bracket

(2)

Fuel filler pipe protector

(8)

Drain filter bracket A

(13)

Lower bracket

(3)

Clip

(9)

Drain filter bracket B

(4)

Neck holder A

(10)

Drain tube

Tightening torque: N·m (kgf-m, ft-lb)

(5)

Neck holder B

(11)

Tube clamp

T:

7.5 (0.8, 5.5)

(6)

Fuel filler pipe

∗If the drain filter bracket A is removed from the drain filter, be sure to replace the drain filter and drain filter bracket A with new parts.
11. FUEL PUMP

(1)

Fuel filter ASSY

(7)

Pressure regulator cap

(13)

Spring

(2)

Fuel level sensor

(8)

Fuel pump holder

(14)

Fuel chamber ASSY

(3)

O-ring

(9)

Connector cable

(15)

Clip

(4)

O-ring

(10)

O-ring

(16)

O-ring

(5)

Back-up ring

(11)

Spacer

(6)

Pressure regulator

(12)

Fuel pump

12. ENGINE WIRING HARNESS

  • Structural diagram 1

    (1)

    Throttle position sensor connector

    (2)

    Multi-wire connector

    (3)

    Guide it over the top of fuel delivery pipe.

    (4)

    Manifold absolute pressure sensor connector

    (5)

    Purge control solenoid valve connector

    (6)

    Secure the clip to the fuel pipe.

    (7)

    PCV hose

    (8)

    Guide it over the top of PCV hose.

    (9)

    Clip

    (10)

    The gap after the stopper is inserted must be 3 mm (0.118in) or less.

    (11)

    M/B connector

    (12)

    ECM connector (For installation and removal, refer to “Engine Control Module (ECM)”.) FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)

    (13)

    Push in the lock lever securely.

    (14)

    Secure the harness to the clip.

    (15)

    Secure the harness case to the harness stay.

  • Structural diagram 2

    (1)

    Thermo control valve ASSY connector

    (2)

    CVT docking connector (30P)

    (3)

    Fuel injector connector (#4) coupling harness connector

    (4)

    Knock sensor LH side coupling harness connector

    (5)

    Secure the clip to the screw hole.

    (6)

    High-pressure fuel pump connector

    (7)

    Fuel injector connector (#2)

    (8)

    Crankshaft position sensor connector

    (9)

    Fuel injector connector (#1)

    (10)

    Fuel pressure sensor connector

    (11)

    Fuel injector connector (#3)

    (12)

    Knock sensor RH side coupling harness connector

    (13)

    Secure the knock sensor RH side coupling harness to the clip. (Secured at the position of the white tape side of the tree clip.)

    (14)

    Tree clip

    (15)

    White tape

    (16)

    Engine wiring harness stay

    (17)

    Secure the clip to the harness case.

    (18)

    Secure the clip to the engine wiring harness stay.

    (19)

    Engine ground (fastened together with harness case)

     

    Tightening torque: N·m (kgf-m, ft-lb)

    T1:

    6.4 (0.7, 4.7)

    T2:

    19 (1.9, 14.0)

  • Structural diagram 3

    (1)

    Outlet engine coolant temperature sensor connector

    (2)

    EGR control valve connector

    (3)

    Oil pressure switch

    (4)

    Engine oil temperature sensor connector

    (5)

    Intake oil control solenoid connector LH

    (6)

    Secure the clip to the screw hole.

    (7)

    Exhaust oil control solenoid connector LH

    (8)

    Inlet engine coolant temperature sensor connector

    (9)

    Oil level switch connector

    (10)

    Exhaust oil control solenoid connector RH

    (11)

    Intake oil control solenoid connector RH

    (12)

    Tumble generator valve actuator connector LH

    (13)

    Ignition coil connector (#4)

    (14)

    Ignition coil connector (#2)

    (15)

    Exhaust camshaft position sensor connector LH

    (16)

    Intake camshaft position sensor connector LH

    (17)

    Intake camshaft position sensor connector RH

    (18)

    Exhaust camshaft position sensor connector RH

    (19)

    Ignition coil connector (#1)

    (20)

    Ignition coil connector (#3)

    (21)

    Tumble generator valve actuator connector RH

    (22)

    Secure a clip to the intake manifold assembly.
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > General Description　
CAUTION
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > General Description　
PREPARATION TOOL
1. SPECIAL TOOL

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

18271AA020

ADJUSTER

Used for installing the fuel injector seal.

18671AA050

GUIDE

Used for installing the fuel injector seal.

20399AG000

STRUT MOUNT SOCKET

Used for removing and installing the engine coolant temperature sensor and engine oil temperature sensor.

 

STRUT MOUNT SOCKET (20099PA000) can also be used.

42075AG690

FUEL HOSE

Used for draining fuel.

 

This is the SUBARU genuine part.

42099AE000

QUICK CONNECTOR RELEASE

Used for removing the quick connector on the fuel hose.

18471AA000

FUEL PIPE ADAPTER

Used for draining fuel.

18460AA180

CHECK BOARD

Used for measuring voltage and resistance of ECM terminals.

42099FL000

ST FUEL PUMP

Used for removing and installing the fuel pump.

—

SUBARU SELECT MONITOR 4

Used for setting of each function and troubleshooting for electrical system.

 

For detailed operation procedures, refer to “Help” of application.
2. GENERAL TOOL

TOOL NAME

REMARKS

TORX® E8

Used for removing and installing EGR control valve stud bolts.

TORX PLUS® 40IP

Used for removing and installing high-pressure fuel pump.

Circuit tester

Used for measuring resistance, voltage and current.

Oscilloscope

Used for inspecting the waveform of each sensor.

Mighty Vac

Used for inspecting the manifold absolute pressure sensor.

DST-i

Used together with Subaru Select Monitor 4.
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Throttle Body　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

3.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

4.

Remove the clip from the air intake boot, and loosen the clamp.

5.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

6.

Disconnect the connector (A) and preheater hose (B).

7.

Remove the throttle body.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Throttle Body　
INSTALLATION
1.

Place a new gasket and install the throttle body.

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

2.

Connect the connector and preheater hose.

3.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

4.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

6.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Throttle Body　
INSPECTION
1. THROTTLE SENSOR (METHOD WITH CIRCUIT TESTER)
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector from ECM. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>REMOVAL

3.

Attach the ST between the ECM, engine wiring harness and the bulkhead wiring harness. ENGINE (DIAGNOSTICS)(H4DO)>General Description>PREPARATION TOOL > HOW TO USE CHECK BOARD

Special tool:

CHECK BOARD (18460AA180)

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

5.

Turn the ignition switch to ON. (Engine OFF)

6.

Measure the voltage between ECM connector terminals.

Throttle sensor

Accelerator pedal

Terminal No.

Standard

Main

Not depressed (full closed)

29 (+) and 30 (−)

Approx. 0.6 — 1.2 V

Depressed (full opened)

Approx. 3.8 — 4.4 V

Sub

Not depressed (full closed)

43 (+) and 30 (−)

Approx. 1.4 — 2.0 V

Depressed (full opened)

Approx. 4.0 — 4.6 V
7.

After inspection, install the related parts in the reverse order of removal.

 

For installation procedures of ECM connectors, refer to Engine Control Module (ECM). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>INSTALLATION

2. THROTTLE SENSOR (METHOD WITH SUBARU SELECT MONITOR)
1.

Turn the ignition switch to ON. (Engine OFF)

2.

Read the accelerator opening angle signal and throttle sensor voltage using Subaru Select Monitor. ENGINE (DIAGNOSTICS)(H4DO)>Data Monitor

Throttle sensor

Accelerator pedal

Acceleration opening angle signal

Standard

Main

Not depressed (full closed)

0.0%

Approx. 0.6 — 1.2 V

Depressed (full opened)

100.0%

Approx. 3.8 — 4.4 V

Sub

Not depressed (full closed)

0.0%

Approx. 1.4 — 2.0 V

Depressed (full opened)

100.0%

Approx. 4.0 — 4.6 V
3. OTHER INSPECTIONS
1.

Check that the throttle body has no deformation, cracks or other damages.

2.

Check that the preheater hose has no cracks, damage or loose part.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Intake Manifold Assembly　
REMOVAL
1.

If the fuel delivery tube is disconnected after removing the intake manifold assembly, perform the following work.

(1)

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

(2)

Open the fuel filler lid and remove the fuel filler cap.

 

This operation is required to release the inner pressure of the fuel tank.

2.

Remove the battery. STARTING/CHARGING SYSTEMS(H4DO)>Battery>REMOVAL

3.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

4.

Remove the clip from the air intake boot, and loosen the clamp.

5.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

6.

When the engine coolant remains before removing the intake manifold assembly

(1)

Disconnect the connector (A).

(2)

Remove the bolts securing the throttle body, and move the throttle body aside so that it does not interfere with the work.

7.

When the engine coolant has been drained before removing the intake manifold assembly

(1)

Disconnect the connector (A), and disconnect the preheater hose (B).

8.

Disconnect the connector (A).

9.

Disconnect the purge hose (B).

10.

Disconnect the PCV hose No. 1 (C).

11.

Remove the bolt securing the fuel pipe.

12.

Disconnect the connector (A).

13.

Remove the fuel delivery tube clamp (B).

14.

Remove the clip (C).

15.

Remove the nut (A) securing the EGR Cooler.

16.

Remove stud bolt (B) using TORX® E8.

17.

Loosen the bolt (C) holding the EGR cooler.

18.

Disconnect the connector (A), connector (B) and terminal (C).

19.

Remove the clip (D) and clip (E) that secure the battery cable assembly.

20.

Remove the connector (A) and connector (B).

21.

Disconnect the brake booster vacuum hose (A).

22.

Disconnect the connector (B), and remove the engine wiring harness from the clip (C).

23.

Remove the clip (D) and clip (E) from the intake manifold assembly.

24.

Disconnect the connector (A).

25.

Cut off the clip (B) using nippers or the similar.

 

Put alignment marks (a) on the clip and the engine wiring harness.

26.

Disengage the claw (A) which holds the battery cable assembly to the bracket, and disengage the claw (B) which holds the engine wiring harness.

27.

Disconnect connector (A) from ECM. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>REMOVAL

28.

Disconnect connector (B) and terminal (C) from the main fuse box.

29.

Remove the engine wiring harness from the clip (D), place it aside so that it does not interfere with work.

30.

Remove the fuel pipe protector.

31.

Remove the fuel delivery tube.

32.

Remove the intake manifold assembly.

  • RH side

  • LH side

33.

Remove the cylinder head plate.

 

Perform this procedure only when required.

34.

Disconnect the fuel delivery pipe. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE C)

35.

Disconnect the fuel delivery pipe (A). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE B)

36.

Disconnect the fuel delivery tube (B). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE A)

37.

Remove the clip (C) from the fuel pipe.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Intake Manifold Assembly　
INSTALLATION
1.

Connect the fuel delivery tube (B). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE A)

2.

Connect the fuel delivery pipe (A). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE B)

3.

Install the clip (C) to the fuel pipe.

4.

Connect the fuel delivery pipe. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE C)

5.

Install the cylinder head plate.

6.

Set a new gasket and install the intake manifold assembly.

 

Be careful not to let the engine wiring harness be caught by the parts.

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

  • RH side

  • LH side

7.

Install the fuel delivery tube.

8.

Install the fuel pipe protector.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

9.

Place the engine wiring harness and attach the engine wiring harness to the clip (D).

10.

Connect terminal (C) and connector (B) to the main fuse box.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

11.

Connect connector (A) to ECM. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>INSTALLATION

12.

Secure the engine wiring harness to the bracket with claw (B), and secure the battery cable assembly with claw (A).

13.

Connect the connector (A).

14.

Hold the engine wiring harness with a new clip (B).

 

Install the clip while aligning the alignment mark of the engine wiring harness.

15.

Install the clip (E) and clip (D) to the intake manifold assembly.

16.

Install the engine wiring harness to the clip (C), and connect the connector (B).

17.

Connect the brake booster vacuum hose (A).

18.

Connect the connector (A) and connector (B).

19.

Secure the battery cable assembly with the clip (A) and clip (B).

20.

Connect the connector (C), connector (D), and the terminal (E).

Tightening torque:

15.5N·m (1.6kfg-m, 11.4ft-lb)

21.

Set a new gasket, and install the stud bolts (B) using TORX® E8.

Tightening torque:

5 N·m (0.5kgf-m, 3.7ft-lb)

22.

Install the nut (A) securing the EGR cooler.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

23.

Tighten the bolt (C) which secures the EGR cooler.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

24.

Connect the connector (A).

25.

Install the fuel delivery tube clamp (B).

26.

Install the clip (C).

27.

Connect the connector (A).

28.

Connect the purge hose (B).

29.

Connect the PCV hose No. 1 (C).

30.

Secure the fuel pipe with the bolt.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

31.

When the engine coolant remains before removing the intake manifold assembly

(1)

Install the throttle body. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Throttle Body>INSTALLATION

32.

When the engine coolant has been drained before removing the intake manifold assembly

(1)

Connect the connector (A) and connect the preheater hoses (B).

33.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

34.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

35.

Install the battery. STARTING/CHARGING SYSTEMS(H4DO)>Battery>INSTALLATION

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Intake Manifold Assembly　
DISASSEMBLY
1.

When the engine coolant has been drained before removing the intake manifold assembly

(1)

Remove the throttle body. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Throttle Body>REMOVAL

2.

Remove the purge control solenoid valve. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>Purge Control Solenoid Valve>REMOVAL

3.

Remove the EGR pipe. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Pipe>REMOVAL

4.

Remove the EGR control valve. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Control Valve>REMOVAL

5.

Remove the manifold absolute pressure sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Manifold Absolute Pressure Sensor>REMOVAL

6.

Remove the collector cover bracket and cushion.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Intake Manifold Assembly　
ASSEMBLY
1.

Install the collector cover bracket and cushion.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Install the manifold absolute pressure sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Manifold Absolute Pressure Sensor>INSTALLATION

3.

Install the EGR control valve. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Control Valve>INSTALLATION

4.

Install the EGR pipe. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Pipe>INSTALLATION

5.

Install the purge control solenoid valve. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>Purge Control Solenoid Valve>INSTALLATION

6.

When the engine coolant has been drained before removing the intake manifold assembly

(1)

Install the throttle body. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Throttle Body>INSTALLATION

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Intake Manifold Assembly　
INSPECTION
1.

Check that the intake manifold assembly and the fuel pipe have no deformation, cracks and other damages.

2.

Check that the hose has no cracks, damage or loose part.

3.

Check tumble generator valve for contamination or clogging.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Tumble Generator Valve　
SPECIFICATION

The tumble generator valve is integrated in the intake manifold assembly.

Refer to “Intake Manifold Assembly” for removal and installation procedures.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Tumble Generator Valve Actuator　
SPECIFICATION

The tumble generator valve actuator cannot be disassembled.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Insulator　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>REMOVAL

6.

Disconnect the connector (A) from the outlet engine coolant temperature sensor.

7.

Remove the bolts securing the engine wiring harness.

8.

Remove the fuel pipe insulator.

(A)

Fuel pipe insulator No. 1

(B)

Fuel pipe insulator No. 2

(C)

Fuel pipe insulator No. 3

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Insulator　
INSTALLATION
1.

Install the fuel pipe insulator.

 

  • If substantial amount of fuel or parts cleaner come into contact with the fuel pipe insulator, replace it with a new fuel pipe insulator.

  • If only small amount of fuel comes into contact with the fuel pipe insulator, wait for the fuel to evaporate before installing it.

2.

Secure the engine wiring harness with the bolts.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Connect the connector to the outlet engine coolant temperature sensor.

4.

Install the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>INSTALLATION

5.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

6.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Insulator　
INSPECTION

Check that the fuel insulator has no deformation, cracks or other damages.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Injector　
REMOVAL
1. FUEL INJECTOR RH
 

  • Be careful not to spill fuel.

  • Catch the fuel from the pipes using a container or cloth.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>REMOVAL > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

6.

Remove the connector (A) and connector (B).

7.

Remove the fuel injector pipe RH together with the fuel injector.

8.

Remove the fuel injector.

2. FUEL INJECTOR LH
 

  • Be careful not to spill fuel.

  • Catch the fuel from the pipes using a container or cloth.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>REMOVAL > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

6.

Remove the high-pressure fuel delivery pipes. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>REMOVAL > HIGH-PRESSURE FUEL DELIVERY PIPE

7.

Move the A/C compressor aside so that it does not interfere with the work.

 

This procedure is required to disconnect the fuel injector #2 connector.

(1)

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL > V-BELT

(2)

Remove the bolt securing the A/C compressor.

(3)

Move the A/C compressor as shown in the figure.

 

Do not bend the pipe portion of the hose pressure discharge and the hose pressure suction.

8.

Disconnect the connector (A) from the coupling harness and remove the clip (B).

9.

Disconnect the connector (C) from the fuel injector #2.

10.

Remove the fuel injector pipe LH together with the fuel injector.

11.

Disconnect the coupling harness from the fuel injector #4.

12.

Remove the fuel injector.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Injector　
INSTALLATION
1. FUEL INJECTOR RH
1.

Prepare for installing the fuel injector using the following new parts. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Injector>REPLACEMENT

  • Fuel injector seal

  • Slider washer

  • Back-up ring

  • O-ring seal

  • Stopper ring

2.

Install the fuel injector holder.

 

Always use a new fuel injector holder.

3.

Align the protrusion of the fuel injector holder to the anti-rotation slot of the fuel injector pipe RH, and install the fuel injector straight to the fuel injector pipe RH.

 

  • Degrease inside of the fuel injector insertion hole of the fuel injector pipe.

  • Check the inside of the fuel injector insertion hole of the fuel injector pipe for foreign materials or damage.

  • Be careful not to allow gasoline to contact with the fuel injector seal and the inside of the mounting hole.

  • Apply liquid paraffin to the O-ring seal and install it.

  • In order to prevent damaging the O-ring seal, do not install the fuel injector to the fuel injector pipe by tilting or twisting it.

  • Make sure there is no gap between the fuel injector pipe and the fuel injector holder.

  • Make sure there is no gap between the fuel injector and the fuel injector holder.

(A)

Protrusion portion

(B)

Anti-rotation slot

(C)

No gap allowed.
4.

Insert the fuel injector pipe RH and fuel injector as a single unit into the cylinder head, and align their positions. Then, evenly press the sections (A) and (B).

 

  • When installing, apply liquid paraffin to the fuel injector seal.

  • In order to prevent damaging the O-ring seal, do not install the fuel injector pipe and fuel injector by tilting them toward the cylinder head.

5.

Tighten the bolts which hold the fuel injector pipe RH.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

6.

Connect the connector (B) and connector (A).

7.

Install the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

8.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

9.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

10.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. FUEL INJECTOR LH
1.

Prepare for installing the fuel injector using the following new parts. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Injector>REPLACEMENT

  • Fuel injector seal

  • Slider washer

  • Back-up ring

  • O-ring seal

  • Stopper ring

2.

Install the fuel injector holder.

 

Always use a new fuel injector holder.

3.

Align the protrusion of the fuel injector holder to the anti-rotation slot of the fuel injector pipe LH, and install the fuel injector straight to the fuel injector pipe LH.

 

  • Degrease inside of the fuel injector insertion hole of the fuel injector pipe.

  • Check the inside of the fuel injector insertion hole of the fuel injector pipe for foreign materials or damage.

  • Be careful not to allow gasoline to contact with the fuel injector seal and the inside of the mounting hole.

  • Apply liquid paraffin to the O-ring seal and install it.

  • In order to prevent damaging the O-ring seal, do not install the fuel injector to the fuel injector pipe by tilting or twisting it.

  • Make sure there is no gap between the fuel injector pipe and the fuel injector holder.

  • Make sure there is no gap between the fuel injector and the fuel injector holder.

(A)

Protrusion portion

(B)

Anti-rotation slot

(C)

No gap allowed.
4.

Connect the coupling harness to the fuel injector #4.

5.

Insert the fuel injector pipe LH and fuel injector as a single unit into the cylinder head, and align their positions. Then, evenly press the sections (A) and (B).

 

  • When installing, apply liquid paraffin to the fuel injector seal.

  • In order to prevent damaging the O-ring seal, do not install the fuel injector pipe and fuel injector by tilting them toward the cylinder head.

6.

Tighten the bolts which hold the fuel injector pipe LH.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

7.

Connect the connector (C) to the fuel injector #2.

8.

Install the clip (B), and connect the connector (A) to the coupling harness.

 

Do not pass the coupling harness through the shaded area (a) shown in the figure.

9.

Install the A/C compressor. AIR CONDITIONER>Compressor>INSTALLATION

10.

Install the V-belts. MECHANICAL(H4DO)>V-belt>INSTALLATION > V-BELT

11.

Install the high-pressure fuel delivery pipe. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE

12.

Install the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

13.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

14.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

15.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

16.

Check refrigerant leaks. AIR CONDITIONER>Refrigerant Leak Check>INSPECTION

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Injector　
REPLACEMENT
1.

Remove the fuel injector holder.

2.

Remove the C-ring (A) and slider washer (B).

3.

Remove the stopper ring (A).

4.

Remove the O-ring (B) and backup ring (C).

5.

Gradually expand the fuel injector seal and remove the fuel injector seal.

 

  • Be careful not to apply too much force when pinching the fuel injector seal, or the fuel injector groove may be damaged.

  • If the tip of the fuel injector assembly is hit or the assembly is dropped, replace the fuel injector assembly with a new part.

6.

Install the fuel injector seal.

(1)

Remove carbon from area (A) shown in the figure (sides of fuel injector and the seal groove).

 

  • Do not attempt to clean the tip.

  • Do not use a wire-brush.

  • If the tip of the fuel injector assembly is hit or the assembly is dropped, replace the fuel injector assembly with a new part.

(2)

Set the ST1 on the fuel injector so that the tapered side (A) (with ST number printed) faces toward the tip of the fuel injector.

Preparation tool:

ST1: ADJUSTER (18271AA020)

(3)

Install new fuel injector seal (A) on ST2.

 

When setting the fuel injector seal on the ST2, be careful not to set it obliquely, or the seal is stretched and become hard to be fixed.

 

Apply liquid paraffin to the fuel injector seal.

Preparation tool:

ST2: GUIDE (18671AA050)

(4)

Set the ST2 with the fuel injector seal installed on the tip of the fuel injector, and push down on the fuel injector seal with fingers and install to the fuel injector groove as shown in the figure.

 

Make sure that the entire perimeter of the fuel injector seal fit in the groove.

Preparation tool:

ST1: ADJUSTER (18271AA020)

ST2: GUIDE (18671AA050)

(5)

Slowly pull up the ST1 toward the tip side of fuel injector while lightly pressing down the fuel injector seal with the ST2 to make the fuel injector seal rest in the fuel injector groove.

 

Be careful not to let the fuel injector seal get caught in the ST1 and the fuel injector groove. If it gets caught, replace the seal with a new part.

Preparation tool:

ST1: ADJUSTER (18271AA020)

ST2: GUIDE (18671AA050)

(A)

Hold
(6)

Slowly pull up the ST1 toward the tip side of fuel injector, and hold in position for at least 5 seconds when the fuel injector seal of the connector side reaches to the straight section of the ST1, and fix the condition of the fuel injector seal.

 

Be careful not to let the fuel injector seal get caught in the ST1 and the fuel injector groove. If it gets caught, replace the seal with a new part.

 

  • The straight section is where the bottom end of the fuel injector seal and the bottom end of the ST1 meet.

  • If it is hard to lift up the ST1, try to slowly lift the ST1 by shaking it side to side.

Preparation tool:

ST1: ADJUSTER (18271AA020)

(7)

After installing the fuel injector seal, check the seal for scratches, crushed area, or dislocation from the groove.

 

If scratches, crushed area, or dislocation from the groove is found, replace the fuel injector seal with a new part again.

7.

Install the fuel injector assembly.

 

If the tip of the fuel injector assembly is hit or the assembly is dropped, replace the fuel injector assembly with a new part.

(1)

Install new backup ring, new O-ring seal and new stopper ring as shown in the figure.

 

  • Check the O-ring seal groove of the fuel injector for foreign materials or damage.

  • Make sure that the orientation of the back-up ring is correct.

  • When installing the stopper ring, the groove should face toward the fuel injector pipe.

  • Make sure that the installation order of the backup ring and O-ring seal is correct.

  • There should be no expansion or ride over at the backup ring gap.

  • After assembling the parts, there should be no foreign materials or damage on the fuel injector seal.

 

Apply liquid paraffin to the O-ring seal.

(A)

Back-up ring

(D)

Back-up ring gap

(F)

Expansion

(B)

O-ring seal

(E)

Ride over

(G)

Groove

(C)

Stopper ring

(2)

Install a C-ring and new slider washer.

 

When installing the slider washer, the groove side (a) should face toward the fuel injector.

(A)

Slider washer

(B)

C-ring
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Injector　
INSPECTION
1.

Check that the fuel injector has no deformation, cracks or other damages.

2.

Measure the resistance between fuel injector terminals.

Terminals No.

Standard

1 and 2

Approx. 1.5 Ω (when 20°C (68°F))
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Pressure Sensor　
REMOVAL
 

  • Be careful not to spill fuel.

  • Catch the fuel from the pipes using a container or cloth.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>REMOVAL

6.

Remove the fuel injector RH. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Injector>REMOVAL > FUEL INJECTOR RH

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Pressure Sensor　
INSTALLATION
1.

Prepare for installing the fuel injector using the following new parts. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Injector>REPLACEMENT

  • Fuel injector seal

  • Slider washer

  • Back-up ring

  • O-ring seal

  • Stopper ring

2.

Install the fuel injector holder.

 

Always use a new fuel injector holder.

3.

Align the protrusion of the fuel injector holder to the anti-rotation slot of the fuel injector pipe RH, and install the fuel injector straight to the fuel injector pipe RH.

 

  • Always use a new fuel injector pipe RH.

  • Check the inside of the fuel injector insertion hole of the fuel injector pipe for foreign materials or damage.

  • Be careful not to allow gasoline to contact with the fuel injector seal and the inside of the mounting hole.

  • Apply liquid paraffin to the O-ring seal and install it.

  • In order to prevent damaging the O-ring seal, do not install the fuel injector to the fuel injector pipe by tilting or twisting it.

  • Make sure there is no gap between the fuel injector pipe and the fuel injector holder.

  • Make sure there is no gap between the fuel injector and the fuel injector holder.

(A)

Protrusion portion

(B)

Anti-rotation slot

(C)

No gap allowed.
4.

Insert the fuel injector pipe RH and fuel injector as a single unit into the cylinder head, and align their positions. Then, evenly press the sections (A) and (B).

 

  • When installing, apply liquid paraffin to the fuel injector seal.

  • In order to prevent damaging the O-ring seal, do not install the fuel injector pipe and fuel injector by tilting them toward the cylinder head.

5.

Tighten the bolts which hold the fuel injector pipe RH.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

6.

Temporarily tighten the fuel pressure sensor until it cannot be turned by hand.

 

Always use a new fuel pressure sensor.

7.

Tighten the fuel pressure sensor.

 

  • Be careful not to spill oil on the screw sections of the fuel pressure sensor and the fuel injector pipe RH.

  • Be careful not to let foreign matter enter into the fuel pressure sensor during installation.

  • The sensor should be installed perpendicularly to the fuel pressure sensor’s threaded hole of the fuel injector pipe RH, and tightened to the specified torque.

  • Do not recheck the tightening torque after tightening the fuel pressure sensor with specified torque.

Tightening torque:

46 N·m (4.7kgf-m, 33.9ft-lb)

8.

Connect the connector (A) and connector (B).

9.

Install the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

10.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

11.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

12.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Pressure Sensor　
INSPECTION

Check that the fuel pressure sensor has no deformation, cracks or other damages.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > High Pressure Fuel Pump　
REMOVAL
1. HIGH-PRESSURE FUEL PUMP
 

  • Be careful not to spill fuel.

  • Catch the fuel from the pipes using a container or cloth.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the high-pressure fuel delivery pipes. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>REMOVAL > HIGH-PRESSURE FUEL DELIVERY PIPE

6.

Disconnect the connector.

7.

Using TORX PLUS® 40IP, remove the high-pressure fuel pump.

8.

Remove the fuel pump lifter.

2. HIGH-PRESSURE FUEL PUMP CASE
1.

Remove the high-pressure fuel pump. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Pump>REMOVAL > HIGH-PRESSURE FUEL PUMP

2.

Remove the high-pressure fuel pump case.

3.

Remove liquid gasket from the high-pressure fuel pump case and the cam carrier assembly LH.

3. FUEL DELIVERY PIPE
1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Remove the battery. STARTING/CHARGING SYSTEMS(H4DO)>Battery>REMOVAL

3.

Remove the fuel pipe protector.

4.

Disconnect the fuel delivery pipe A. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE C)

5.

Remove the fuel delivery pipe B.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > High Pressure Fuel Pump　
INSTALLATION
1. HIGH-PRESSURE FUEL PUMP
1.

Install the fuel pump lifter.

 

  • Apply engine oil to the side of the high-pressure fuel pump case and to the bottom surface of the fuel pump lifter.

  • After installing the fuel pump lifter, rotate the crankshaft in order to set the fuel pump lifter to the lowest position.

2.

Set a new O-ring, and install the high-pressure fuel pump using TORX PLUS® 40IP.

Tightening torque:

21 N·m (2.1kgf-m, 15.5ft-lb)

3.

Connect the connector.

4.

Install the high-pressure fuel delivery pipe. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE

5.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

6.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. HIGH-PRESSURE FUEL PUMP CASE
1.

Apply liquid gasket to the mating surfaces of fuel pump case, and install the high-pressure fuel pump case.

 

  • Before applying liquid gasket, degrease the old liquid gasket seal surface of the high-pressure fuel pump case and the cam carrier assembly LH.

  • Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter:

3.5±1 mm (0.1378±0.0394in)

(A)

Within 1 mm (within 0.0394in)

(B)

3.5 mm (0.1378in)

(C)

Chamfer edge
2.

Install the high-pressure fuel pump case.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

3.

Install the high-pressure fuel pump. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Pump>INSTALLATION > HIGH-PRESSURE FUEL PUMP

3. FUEL DELIVERY PIPE
1.

Using a new gasket, install the fuel delivery pipe B to the high-pressure fuel pump.

Tightening torque:

48 N·m (4.9kgf-m, 35.4ft-lb)

2.

Connect the fuel delivery pipe A. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE C)

3.

Install the fuel pipe protector.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

4.

Install the battery. STARTING/CHARGING SYSTEMS(H4DO)>Battery>INSTALLATION

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > High Pressure Fuel Pump　
INSPECTION
1. CHECK HIGH-PRESSURE FUEL PUMP
1.

Check that the high-pressure fuel pump has no deformation, cracks or other damages.

2.

Measure the resistance between high-pressure fuel pump terminals.

Terminal No.

Standard

1 and 2

0.5Ω (when 20°C (68°F))
2. CHECK THE HIGH-PRESSURE FUEL PUMP CASE AND FUEL PUMP LIFTER
1.

Check that the high-pressure fuel pump case and the fuel pump lifter have no deformation, cracks or other damages.

2.

Check the clearance between the fuel pump lifter and high-pressure fuel pump case bore. Check the clearance between fuel pump lifter and high-pressure fuel pump case bore by measuring the outer diameter of fuel pump lifter and the inner diameter of high-pressure fuel pump case bore respectively.

(1)

Measure the outer diameter of fuel pump lifter with a micrometer.

 

  • Measurement should be performed at a temperature of 20°C (68°F).

  • Measure at several points, and take notes of the value of most worn location.

(2)

Using a caliper gauge, measure the inner diameter of high-pressure fuel pump case bore.

 

  • Measurement should be performed at a temperature of 20°C (68°F).

  • Measure at several points, and take notes of the value of most worn location.

(3)

Calculate the clearance between the fuel pump lifter and high-pressure fuel pump case bore. If it is not within the standard, replace the fuel pump lifter and high-pressure fuel pump case as a set.

Clearance between fuel pump lifter and high-pressure fuel pump case bore:

Standard

0.055 — 0.108 mm (0.0022 — 0.0043in)

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > High Pressure Fuel Delivery Pipe　
REMOVAL
1. HIGH-PRESSURE FUEL DELIVERY PIPE
 

  • Be careful not to spill fuel.

  • Catch the fuel from the pipes using a container or cloth.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>REMOVAL

6.

Remove the fuel pipe insulator No. 3. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Insulator>REMOVAL

7.

Remove the high-pressure fuel delivery pipes.

2. HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY
 

  • Be careful not to spill fuel.

  • Catch the fuel from the pipes using a container or cloth.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>REMOVAL

6.

Remove the fuel pipe insulator No. 1, fuel pipe insulator No. 2 and fuel pipe insulator No. 3. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Insulator>REMOVAL

7.

Remove the flare nut (A) and bolt (B), and then remove the high-pressure fuel delivery pipe assembly.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > High Pressure Fuel Delivery Pipe　
INSTALLATION
1. HIGH-PRESSURE FUEL DELIVERY PIPE
1.

Temporarily tighten the flare nut of the high-pressure fuel delivery pipe by hand until it seats, and tighten the flare nuts on both ends.

 

  • Always use a new high-pressure fuel delivery pipe.

  • Check that the seal surface of the fuel injector pipe LH and the high-pressure fuel pump have no deformation, cracks or other damages.

  • Check that the seal surface of the fuel injector pipe LH and the high-pressure fuel pump have no foreign materials.

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

2.

Install the fuel pipe insulator No. 3. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Insulator>INSTALLATION

3.

Install the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>INSTALLATION

4.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

5.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY
1.

Install the high-pressure fuel delivery pipe assembly.

 

  • Always use a new high-pressure fuel delivery pipe assembly.

  • Check that the seal surface of the fuel injector pipe have no deformation, cracks or other damages.

  • Check that the seal surface of the fuel injector pipe have no foreign materials.

(1)

Temporarily tighten the flare nut (A) to the fuel injector pipe by hand until it is seated, and secure the high-pressure fuel delivery pipe assembly to the water pipe assembly using bolts (B).

Tightening torque:

T1: 6.4N·m (0.7kgf-m, 4.7ft-lb)

(2)

Tighten the flare nuts (A).

Tightening torque:

T2: 25 N·m (2.5kgf-m, 18.4ft-lb)

2.

Install the fuel pipe insulator No. 1, fuel pipe insulator No. 2 and fuel pipe insulator No. 3. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Insulator>INSTALLATION

3.

Install the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>INSTALLATION

4.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

5.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > High Pressure Fuel Delivery Pipe　
INSPECTION

Check that the high-pressure fuel delivery pipe and the high-pressure fuel delivery pipe assembly have no deformation, cracks and other damages.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Wiring Harness　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>REMOVAL

6.

Remove the fuel insulator. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Insulator>REMOVAL

7.

Disconnect each connector to remove the engine wiring harness. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>General Description>COMPONENT > ENGINE WIRING HARNESS

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Wiring Harness　
INSTALLATION
1.

Set the engine wiring harness, and connect each connector. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>General Description>COMPONENT > ENGINE WIRING HARNESS

 

  • If the clip is damaged, replace it with a new part.

  • Before replacing the clip, put an alignment mark (a) on both engine wiring harness and clip to remove the clip, and then align to the alignment mark (a) to attach a new clip to the engine wiring harness.

2.

Install the fuel insulator. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Insulator>INSTALLATION

3.

Install the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>INSTALLATION

4.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

5.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Wiring Harness　
INSPECTION

Check that the engine wiring harness does not have deformation, cracks and any other damage.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Coolant Temperature Sensor　
REMOVAL
1. OUTLET ENGINE COOLANT TEMPERATURE SENSOR
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

3.

Remove the generator. STARTING/CHARGING SYSTEMS(H4DO)>Generator>REMOVAL

4.

Disconnect the connector (A) and remove the outlet engine coolant temperature sensor using the ST.

 

STRUT MOUNT SOCKET (20099PA000) can also be used.

Preparation tool:

ST: STRUT MOUNT SOCKET (20399AG000)

2. INLET ENGINE COOLANT TEMPERATURE SENSOR
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

3.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

4.

Disconnect the connector (A) and disconnect the connector (B) from the chain cover.

5.

Remove the bolt (C) securing the harness stay, and remove the inlet engine coolant temperature sensor.

6.

Remove the inlet engine coolant temperature sensor from the harness stay.

 

Do not remove the inlet engine coolant temperature sensor harness from the harness stay unless replacing the inlet engine coolant temperature sensor.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Coolant Temperature Sensor　
INSTALLATION
1. OUTLET ENGINE COOLANT TEMPERATURE SENSOR
1.

Place a new gasket and install the outlet engine coolant temperature sensor using the ST.

 

STRUT MOUNT SOCKET (20099PA000) can also be used.

Preparation tool:

ST: STRUT MOUNT SOCKET (20399AG000)

Tightening torque:

16 N·m (1.6kgf-m, 11.8ft-lb)

2.

Connect the connector.

3.

Install the generator. STARTING/CHARGING SYSTEMS(H4DO)>Generator>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

5.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

2. INLET ENGINE COOLANT TEMPERATURE SENSOR
1.

Install the inlet engine coolant temperature sensor to the harness stay.

 

If the clip of the inlet engine coolant temperature sensor harness is damaged, replace it with a new inlet engine coolant temperature sensor.

2.

Place a new gasket and install the inlet engine coolant temperature sensor.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

3.

Install the inlet engine coolant temperature sensor stay with the bolt (C).

Tightening torque:

8.5N·m (0.9kgf-m, 6.3ft-lb)

4.

Install the connector (B) to the chain cover and connect the connector (A).

 

  • If the clip (a) of the connector (B) is damaged, replace it with a new clip.

  • If the installation part for the clip (a) of the connector (B) is damaged, replace it with a new inlet engine coolant temperature sensor.

  • If the clip (a) has been replaced, put a marking (b) to ensure that the replacement of clips can be identified.

5.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

7.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Coolant Temperature Sensor　
INSPECTION
1.

Check that the engine coolant temperature sensor has no deformation, cracks or other damages.

2.

Immerse the engine coolant temperature sensor and a thermometer in water.

 

Take care not to allow water to get into the engine coolant temperature sensor connector. Completely remove any water inside.

(A)

Thermometer

(B)

Engine coolant temperature sensor

(C)

Hexagonal part height: To approx.1/3
3.

Raise water temperature gradually, measure the resistance between the engine coolant temperature sensor terminals when the temperature is 20°C (68°F) and 80°C (176°F).

 

Agitate the water for even temperature distribution.

Water temperature

Terminal No.

Standard

20°C (68°F)

1 and 2

2.45±0.2 kΩ

80°C (176°F)

0.318±0.013 kΩ
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Oil Temperature Sensor　
REMOVAL
 

If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emission of smoke or causing a fire.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector (A), and remove the engine oil temperature sensor from the chain cover using the ST.

 

STRUT MOUNT SOCKET (20099PA000) can also be used.

Preparation tool:

ST: STRUT MOUNT SOCKET (20399AG000)

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Oil Temperature Sensor　
INSTALLATION
1.

Set a new gasket, install the engine oil temperature sensor to the chain cover using the ST.

 

STRUT MOUNT SOCKET (20099PA000) can also be used.

Preparation tool:

ST: STRUT MOUNT SOCKET (20399AG000)

Tightening torque:

16 N·m (1.6kgf-m, 11.8ft-lb)

2.

Connect the connector.

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Oil Temperature Sensor　
INSPECTION
1.

Check that the engine oil temperature sensor has no deformation, cracks or other damages.

2.

Immerse the engine oil temperature sensor and a thermometer in water.

 

Take care not to allow water to get into the engine oil temperature sensor connector. Completely remove any water inside.

(A)

Thermometer

(B)

Engine oil temperature sensor

(C)

Hexagonal part height: To approx.1/3
3.

Raise water temperature gradually, measure the resistance between the engine oil temperature sensor terminals when the temperature is 20°C (68°F) and 80°C (176°F).

 

Agitate the water for even temperature distribution.

Water temperature

Terminal No.

Standard

20°C (68°F)

1 and 2

2.45±0.2 kΩ

80°C (176°F)

0.318±0.013 kΩ
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Crankshaft Position Sensor　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Disconnect the connector (A).

6.

Remove the bolt securing the engine ground and the harness case.

7.

Remove the clip (B) from the engine wiring harness bracket.

8.

Disconnect the connector (A) and remove the crankshaft position sensor.

 

Do not apply excessive force to the harness. Otherwise the harness may be damaged.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Crankshaft Position Sensor　
INSTALLATION
1.

Install the crankshaft position sensor and connect the connector.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Install the engine ground and the harness case.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

3.

Install the clip (B) to the engine wiring harness bracket.

4.

Connect the connector (A).

5.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

6.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Crankshaft Position Sensor　
INSPECTION
1. CRANKSHAFT POSITION SENSOR
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Prepare an oscilloscope.

3.

Disconnect the connector from ECM. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>REMOVAL

4.

Attach the ST between the ECM, engine wiring harness and the bulkhead wiring harness. ENGINE (DIAGNOSTICS)(H4DO)>General Description>PREPARATION TOOL > HOW TO USE CHECK BOARD

Special tool:

CHECK BOARD (18460AA180)

5.

Connect the probe to ST.

Terminal No.

Probe

(E158) No. 66

+

(B134) No. 69

−
6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

7.

Start the engine and let it idle.

8.

Check the waveforms and voltage.

 

For waveform and voltage, refer to “Control Module (ECM) I/O Signal”. ENGINE (DIAGNOSTICS)(H4DO)>Control Module I/O Signal

9.

After inspection, install the related parts in the reverse order of removal.

 

For installation procedures of ECM connectors, refer to Engine Control Module (ECM). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>INSTALLATION

2. OTHER INSPECTIONS

Check that the crankshaft position sensor has no deformation, cracks or other damages.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Crankshaft Position Sensor Plate　
REMOVAL

The crankshaft position sensor plate is tightened together with the drive plate; therefore, refer to “Drive Plate” for removal procedure. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Plate>REMOVAL

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Crankshaft Position Sensor Plate　
INSTALLATION

The crankshaft position sensor plate is tightened together with the drive plate; therefore, refer to “Drive Plate” for installation procedure. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Plate>INSTALLATION

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Crankshaft Position Sensor Plate　
INSPECTION

Check that the crankshaft position sensor plate has no deformation, cracks or other damages.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Camshaft Position Sensor　
REMOVAL
1. INTAKE SIDE
•
RH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

3.

Disconnect the connector (A) and remove the camshaft position sensor.

•
LH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector (A) and remove the camshaft position sensor.

2. EXHAUST SIDE
•
RH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Lift up the vehicle.

3.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

4.

Disconnect the connector (A) and remove the camshaft position sensor.

•
LH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Lift up the vehicle.

3.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

4.

Disconnect the connector (A) and remove the camshaft position sensor.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Camshaft Position Sensor　
INSTALLATION
1. INTAKE
•
RH SIDE
1.

Install the camshaft position sensor with new O-ring.

 

Apply engine oil to O-ring.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Connect the connector.

3.

Install the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

•
LH SIDE
1.

Install the camshaft position sensor with new O-ring.

 

Apply engine oil to O-ring.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Connect the connector.

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. EXHAUST
•
RH SIDE
1.

Install the camshaft position sensor with new O-ring.

 

Apply engine oil to O-ring.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Connect the connector.

3.

Install the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>INSTALLATION

4.

Lower the vehicle.

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

•
LH SIDE
1.

Install the camshaft position sensor with new O-ring.

 

Apply engine oil to O-ring.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Connect the connector.

3.

Install the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>INSTALLATION

4.

Lower the vehicle.

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Camshaft Position Sensor　
INSPECTION
1. CAMSHAFT POSITION SENSOR
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Prepare an oscilloscope.

3.

Disconnect the connector from ECM. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>REMOVAL

4.

Attach the ST between the ECM, engine wiring harness and the bulkhead wiring harness. ENGINE (DIAGNOSTICS)(H4DO)>General Description>PREPARATION TOOL > HOW TO USE CHECK BOARD

Special tool:

CHECK BOARD (18460AA180)

5.

Connect the probe to ST.

Camshaft position sensor

Terminal No.

Probe

Intake

RH

(E158) No. 78

+

LH

(E158) No. 77

+

Exhaust

RH

(E158) No. 65

+

LH

(E158) No. 64

+

RH and LH

(B134) No. 69

−
6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

7.

Start the engine and let it idle.

8.

Check the waveforms and voltage.

 

For waveform and voltage, refer to “Control Module (ECM) I/O Signal”. ENGINE (DIAGNOSTICS)(H4DO)>Control Module I/O Signal

9.

After inspection, install the related parts in the reverse order of removal.

 

For installation procedures of ECM connectors, refer to Engine Control Module (ECM). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>INSTALLATION

2. OTHER INSPECTIONS

Check that the camshaft position sensor has no deformation, cracks or other damages.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Oil Control Solenoid　
REMOVAL
 

If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emission of smoke or causing a fire.

1. INTAKE
•
RH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

3.

Disconnect the connector (A) and remove the oil control solenoid.

4.

Remove the backup ring from the oil control solenoid.

•
LH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector (A) and remove the oil control solenoid.

3.

Remove the backup ring from the oil control solenoid.

2. EXHAUST
•
RH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

3.

Disconnect the connector (A) and remove the oil control solenoid.

4.

Remove the backup ring from the oil control solenoid.

•
LH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector (A) and remove the oil control solenoid.

3.

Remove the backup ring from the oil control solenoid.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Oil Control Solenoid　
INSTALLATION
1. INTAKE
•
RH SIDE
1.

Install the backup ring to the oil control solenoid.

2.

Using a new O-ring, install the oil control solenoid.

 

Apply engine oil to O-ring.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Connect the connector.

4.

Install the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

•
LH SIDE
1.

Install the backup ring to the oil control solenoid.

2.

Using a new O-ring, install the oil control solenoid.

 

Apply engine oil to O-ring.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Connect the connector.

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. EXHAUST SIDE
•
RH SIDE
1.

Install the backup ring to the oil control solenoid.

2.

Using a new O-ring, install the oil control solenoid.

 

Apply engine oil to O-ring.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Connect the connector.

4.

Install the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

•
LH SIDE
1.

Install the backup ring to the oil control solenoid.

2.

Using a new O-ring, install the oil control solenoid.

 

Apply engine oil to O-ring.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Connect the connector.

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Oil Control Solenoid　
INSPECTION
1.

Check that the oil control solenoid has no deformation, cracks or other damages.

2.

Measure the resistance between the oil control solenoid terminals.

Terminal No.

Standard

1 and 2

7.25±0.4 Ω (when 20°C (68°F))
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Knock Sensor　
REMOVAL
1. RH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>REMOVAL

6.

Remove the bolt (A) securing the engine wiring harness.

7.

Disconnect the connector (B) and remove the clip (C).

8.

Remove the coupling harness from the clip (D).

9.

Remove the knock sensor together with the coupling harness, and disconnect the coupling harness.

2. LH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

5.

Remove the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>REMOVAL

6.

Disconnect the connector (A).

7.

Remove the bolt securing the engine ground and the harness case, and remove the clip (B).

8.

Remove the bolts securing the engine wiring harness stay, and remove the engine wiring harness stay.

9.

Disconnect the connector (C) and remove the clip (D) and clip (E).

10.

Remove the knock sensor together with the coupling harness using a claw-foot wrench.

11.

Disconnect the coupling harness.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Knock Sensor　
INSTALLATION
1. RH SIDE
1.

Connect the coupling harness and install the knock sensor.

 

  • Knock sensor must be positioned so that the connector center comes within the range shown in the figure.

  • Make sure that the knock sensor and its connector do not touch the adjacent parts.

Tightening torque:

24 N·m (2.4kgf-m, 17.7ft-lb)

(a)

Front of engine
2.

Install the coupling harness to the clip (D).

3.

Connect the connector (B) and install the clip (C).

4.

Install the engine wiring harness with the bolt (A).

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

5.

Install the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>INSTALLATION

6.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

7.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

8.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. LH SIDE
1.

Connect the coupling harness and install the knock sensor using a claw-foot wrench.

 

  • Knock sensor must be positioned so that the connector center comes within the range shown in the figure.

  • Make sure that the knock sensor and its connector do not touch the adjacent parts.

    (a)

    Front of engine

Tightening torque:

Calculation formula

T = 24 N·m (2.4 kgf-m, 17.7ft-lb) × L1/ (L1+L2)

T: Reading of the torque wrench

L1: Effective length of the torque wrench

L2: Effective length of the crowfoot wrench

 

If the effective length of the tool used is unknown, consult the manufacturer of the tool.

(a) Effective length of the crowfoot wrench

(b) Effective length of the torque wrench

(c) Center of the open end of crowfoot wrench

(d) Center of drive square of the torque wrench

(e) Center of the position where a force is applied by hand
2.

Install the clip (D) and clip (E), and connect the connector (C).

3.

Install the engine wiring harness stay and install the clip (B).

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

4.

Install the engine ground and the harness case.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

5.

Connect the connector (A).

6.

Install the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>INSTALLATION

7.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

8.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

9.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Knock Sensor　
INSPECTION
1.

Check that the knock sensor has no deformation, cracks or other damages.

2.

Measure the resistance between knock sensor terminals.

Terminal No.

Standard

1 and 2

560±28 kΩ
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Throttle Position Sensor　
SPECIFICATION

The throttle body cannot be disassembled.

Refer to “Throttle Body” for removal and installation procedures.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Mass Air Flow and Intake Air Temperature Sensor　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector (A) and remove the mass air flow and intake air temperature sensor.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Mass Air Flow and Intake Air Temperature Sensor　
INSTALLATION
1.

Install the mass air flow and intake air temperature sensor, and connect the connector.

Tightening torque:

1 N·m (0.1kgf-m, 0.7ft-lb)

2.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Mass Air Flow and Intake Air Temperature Sensor　
INSPECTION
1. CHECK THE MASS AIR FLOW SENSOR UNIT
1.

Remove the mass air flow and intake air temperature sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Mass Air Flow and Intake Air Temperature Sensor>REMOVAL

 

Do not disconnect the connector.

2.

Turn the ignition switch to ON. (Engine OFF)

3.

Using the Subaru Select Monitor, read the intake air amount. ENGINE (DIAGNOSTICS)(H4DO)>Data Monitor

4.

Check that the intake air amount changes when air is blown to the mass air flow sensor unit in the arrow direction.

 

Be careful that no dust enter inside the unit when air is blown.

5.

After inspection, install the related parts in the reverse order of removal.

2. CHECK THE INTAKE AIR TEMPERATURE SENSOR UNIT

Measure the resistance between intake air temperature sensor terminals.

Temperature

Terminal No.

Standard

−20°C (−4°F)

2 and 4

16.0±2.4 kΩ

20°C (68°F)

2.45±0.24 kΩ

60°C (140°F)

0.58±0.087 kΩ
3. OTHER INSPECTIONS
1.

Check that the mass air flow and intake air temperature sensor has no deformation, cracks or other damages.

2.

Check that the mass air flow and intake air temperature sensor has no dirt.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Manifold Absolute Pressure Sensor　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Disconnect the connector (A) and remove the manifold absolute pressure sensor.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Manifold Absolute Pressure Sensor　
INSTALLATION
1.

Using a new O-ring, install the manifold absolute pressure sensor.

Tightening torque:

3.4N·m (0.3kgf-m, 2.5ft-lb)

2.

Connect the connector.

3.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Manifold Absolute Pressure Sensor　
INSPECTION
1.

Check that the manifold absolute pressure sensor has no deformation, cracks or other damages.

2.

Using new dry cell batteries, connect the battery positive terminal to terminal No. 3 and the battery ground terminal to terminal No. 1, and connect the circuit tester positive terminal to terminal No. 2 and the circuit tester ground terminal to terminal No. 1.

 

  • Using a circuit tester, check that the initial voltage of each dry-cell battery is 1.6 V or more. And also check that the voltage of three batteries in series is between 4.8 — 5.2 V.

  • For power supply, 5 V DC constant voltage power source can also be used.

3.

Check the voltage at a normal atmospheric pressure.

 

The atmospheric pressure at higher altitude is lower than normal. Therefore, the voltage is lower than the standard value.

Terminals No.

Standard

2 (+) and 1 (−)

Approx. 4.2 V (when 25°C (77°F))
4.

Connect the Mighty Vac to the pressure port (A) of manifold absolute pressure sensor.

5.

Check the voltage when generating vacuum using Mighty Vac.

 

Do not reduce the pressure that exceeds −105 kPa (−1.07 kg/cm2, −15.2psi). Doing so may damage the manifold absolute pressure sensor.

 

When vacuum occurs at the pressure port of manifold absolute pressure sensor, the voltage will drop from the value as in step 3.

Pressure

Terminals No.

Standard

−105 kPa (−1.07 kg/cm2, −15.2psi)

2 (+) and 1 (−)

Approx. 1 V (when 25°C (77°F))
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Front Oxygen (A/F) Sensor　
REMOVAL
 

Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Lift up the vehicle.

3.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

4.

Apply spray-type lubricant (004301003) or equivalent to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more.

5.

Disconnect the connector (A) and remove the front oxygen (A/F) sensor.

 

When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Front Oxygen (A/F) Sensor　
INSTALLATION
 

If lubricant is spilt over the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire.

1.

Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier.

 

Never apply anti-seize compound to the protector of front oxygen (A/F) sensor.

Anti-seize compound:

NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent

2.

Install the front oxygen (A/F) sensor and connect the connector.

Tightening torque:

21 N·m (2.1kgf-m, 15.5ft-lb)

3.

Install the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>INSTALLATION

4.

Lower the vehicle.

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Front Oxygen (A/F) Sensor　
INSPECTION
1.

Check that the front oxygen (A/F) sensor has no deformation, cracks or other damages.

2.

Measure the resistance between front oxygen (A/F) sensor terminals.

Terminal No.

Standard

1 and 2

2.0±0.2 Ω (when 20°C (68°F))
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Rear Oxygen Sensor　
REMOVAL
 

Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Lift up the vehicle.

3.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

4.

Apply spray-type lubricant (004301003) or equivalent to the threaded portion of rear oxygen sensor, and leave it for one minute or more.

5.

Disconnect the connector (A), and remove the rear oxygen sensor.

 

When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Rear Oxygen Sensor　
INSTALLATION
 

If lubricant is spilt over the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire.

1.

Before installing rear oxygen sensor, apply the anti-seize compound only to the threaded portion of rear oxygen sensor to make the next removal easier.

 

Never apply anti-seize compound to the protector of rear oxygen sensor.

Anti-seize compound:

NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent

2.

Install the rear oxygen sensor and connect the connector.

 

Do not cross the rear oxygen sensor harness with the ground cord during installation.

Tightening torque:

21 N·m (2.1kgf-m, 15.5ft-lb)

3.

Install the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>INSTALLATION

4.

Lower the vehicle.

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Rear Oxygen Sensor　
INSPECTION
1.

Check that the rear oxygen sensor has no deformation, cracks or other damages.

2.

Measure the resistance between rear oxygen sensor terminals.

Terminal No.

Standard

1 and 2

5.6+0.8−0.6 Ω (when 20°C (68°F))
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > SI-DRIVE (SUBARU Intelligent Drive) Selector　
SPECIFICATION

SI-DRIVE (SUBARU Intelligent Drive) selector is integrated as a unit with the EyeSight steering switch.

For removal, installation and inspection, refer to “EyeSight” section. EyeSight>Switches and Harness

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Control Module (ECM)　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector in numerical order as shown in the figure.

 

Make sure that the lock is released before moving the lever in order to avoid damaging the connector.

 

To disconnect the connector, press the portion (a) shown in the figure to release the lock and move the lever in the direction of arrow.

3.

Remove the ECM from vehicle.

4.

Remove the ECM bracket.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Control Module (ECM)　
INSTALLATION
 

When the ECM of model with immobilizer has been replaced, be sure to perform the registration of immobilizer system.

  • For model without keyless access with push button start, refer to the Type B in “REGISTRATION MANUAL FOR IMMOBILIZER”.

  • For model with keyless access with push button start, refer to the Type D in “REGISTRATION MANUAL FOR IMMOBILIZER”.

 

When replacing the ECM, be careful not to use the ECM of wrong specification to avoid any damage on the fuel injection system.

1.

Install the ECM bracket.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

2.

Temporarily install the ECM to the vehicle, tighten the fasteners in numerical order as shown in the figure.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

3.

Connect the connector in numerical order as shown in the figure.

 

To prevent damage to the connector, when connecting the connector, insert the connector straight in until it stops, and while maintaining the position, lock the lever.

 

Check that the lever is located at the position shown in the figure (position beyond the lock portion (a)).

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Engine Control Module (ECM)　
INSPECTION

Check that the ECM has no deformation, cracks or other damages.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Main Relay　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the main relay from main fuse box.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Main Relay　
INSTALLATION
1.

Install the main relay to the main fuse box.

2.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Main Relay　
INSPECTION
1.

Check that there is no deformation, cracks or other damages.

2.

Check the resistance between terminals.

Terminals No.

Inspection conditions

Standard

1 — 3

Always

1 MΩ or more

1 — 3

Apply battery voltage between terminals 2 and 4.

Less than 1 Ω
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Pump Relay　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the fuel pump relay from the main fuse box.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Pump Relay　
INSTALLATION
1.

Install the fuel pump relay to the main fuse box.

2.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Pump Relay　
INSPECTION
1.

Check that there is no deformation, cracks or other damages.

2.

Check the resistance between terminals.

Terminal No.

Inspection conditions

Standard

3 — 4

Always

1 MΩ or more

3 — 4

Apply battery voltage between terminals 1 and 2.

Less than 1 Ω
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel　
PROCEDURE
1. RELEASING OF FUEL PRESSURE
 

Place “NO OPEN FLAMES” signs near the working area.

 

Be careful not to spill fuel.

1.

Remove the fuse of fuel pump from main fuse box.

2.

Start the engine and run it until it stalls.

3.

After the engine stalls, crank it for five more seconds.

4.

Turn the ignition switch to OFF.

5.

Install the fuse of fuel pump to the main fuse box.

2. DRAINING FUEL (WITH SUBARU SELECT MONITOR)
 

Place “NO OPEN FLAMES” signs near the working area.

 

Be careful not to spill fuel.

 
1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Remove the fuel delivery tube clamp from the fuel delivery tube.

3.

Disconnect the quick connector on the fuel delivery tube from the fuel pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE A)

4.

Connect the ST to the fuel pipe assembly.

 

The ST is a SUBARU genuine part.

Special tool:

FUEL HOSE (42075AG690)

5.

Connect the gasoline proof hose to ST and put the end of the hose in the container.

6.

Drive the fuel pump and drain the fuel using Subaru Select Monitor. ENGINE (DIAGNOSTICS)(H4DO)>Active Test

 

  • Be careful not to spill fuel.

  • Always collect fuel using a dedicated fuel container.

7.

Install the related parts in the reverse order after draining the fuel.

 

  • Be careful not to spill fuel.

  • Catch the fuel from the tubes using a container or cloth.

  • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

  • When connecting the quick connector, make sure to insert it all the way in before locking the slider.

  • When it is difficult to lock the slider, check that the connector is fully inserted.

  • After locking the slider, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

 
3. DRAINING FUEL (WITH OTHER THAN SUBARU SELECT MONITOR)
 

Place “NO OPEN FLAMES” signs near the working area.

 

Be careful not to spill fuel.

 

If the fuel gauge indicates “F”, perform “DRAINING FUEL PARTIALLY”. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > DRAINING FUEL PARTIALLY

1.

Open the fuel filler lid and remove the fuel filler cap.

2.

Remove the fuel pump assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump>REMOVAL

3.

Remove the fuel sub level sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Sub Level Sensor>REMOVAL

4.

Drain the fuel from the fuel tank using the gasoline proof pump.

 

  • Be careful not to spill fuel.

  • Always collect fuel using a dedicated fuel container.

5.

Install the related parts in the reverse order after draining the fuel.

 

For information about connecting the quick connector on the fuel delivery tube, refer to “Fuel Delivery and Evaporation Lines”. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE D)

4. DRAINING FUEL PARTIALLY
 

Place “NO OPEN FLAMES” signs near the working area.

 

  • Be careful not to spill fuel.

  • Fuel may remain in the fuel filler pipe. Drain the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose before the operation.

1.

Set the vehicle on a lift.

2.

Open the fuel filler lid and remove the fuel filler cap.

3.

Drain the fuel from the fuel filler pipe using the gasoline proof pump and the gasoline proof hose.

 

  • Be careful not to spill fuel.

  • Always collect fuel using a dedicated fuel container.

4.

Lift up the vehicle.

5.

Remove the circulate tube from the clip.

6.

Set a container under the vehicle, and disconnect the circulate tube from the fuel filler pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE D)

 

  • Be careful not to spill fuel.

  • Catch the fuel from fuel filler pipe and circulate tube using a container or cloth.

7.

Connect ST to the circulate tube. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE D)

Preparation tool:

ST: FUEL PIPE ADAPTER (18471AA000)

8.

Connect the hose of gasoline proof pump to the ST and drain the fuel.

 

  • Be careful not to spill fuel.

  • Always collect fuel using a dedicated fuel container.

Special tool:

FUEL PIPE ADAPTER (18471AA000)

9.

Install the related parts in the reverse order after draining the fuel.

 

For information about connecting the quick connector on the circulate tube, refer to “Fuel Delivery and Evaporation Lines”. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE D)

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Tank Protector　
REMOVAL
1.

Lift up the vehicle.

2.

Remove the bolt and clip (A) and remove the fuel tank protector.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Tank Protector　
INSTALLATION
1.

Install the fuel tank protector.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

2.

Lower the vehicle.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Tank Protector　
INSPECTION

Check that the fuel tank protector has no deformation, cracks or other damages.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Tank　
REMOVAL
 

Place “NO OPEN FLAMES” signs near the working area.

 

  • Be careful not to spill fuel.

  • Catch the fuel from the tubes using a container or cloth.

1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Drain fuel. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > DRAINING FUEL (WITH SUBARU SELECT MONITOR)

3.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Remove the rear seat cushion. SEATS>Rear Seat>REMOVAL

5.

Remove the service hole cover of fuel pump.

6.

Disconnect the connector from fuel pump.

7.

Remove the service hole cover of fuel sub level sensor.

8.

Disconnect the connector from the fuel sub level sensor.

9.

Lift up the vehicle.

10.

Remove the fuel tank protector. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Tank Protector>REMOVAL

11.

Remove the rear exhaust pipe and muffler as a single unit.

Rear exhaust pipe:

EXHAUST(H4DO)>Rear Exhaust Pipe>REMOVAL

Muffler:

EXHAUST(H4DO)>Muffler>REMOVAL

12.

Remove the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>REMOVAL

13.

Disconnect the fuel filler hose from the fuel filler pipe assembly.

14.

Disconnect the vent tube (A) from the canister. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE G)

15.

Disconnect the circulate tube (B) from the fuel tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE D)

16.

Disconnect the fuel delivery tube from the fuel pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE A)

17.

Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and remove the fuel tank from the vehicle.

 

  • A helper is required to perform this work.

  • Fuel may remain in the fuel tank. This will cause the left and right sides to be unbalanced. Be careful not to drop it.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Tank　
INSTALLATION
1.

Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band.

 

A helper is required to perform this work.

2.

Tighten the bolts of the fuel tank band in the numerical order shown in the figure.

Tightening torque:

33 N·m (3.4kgf-m, 24.3ft-lb)

3.

Connect the fuel delivery tube to the fuel pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE A)

4.

Connect the vent tube (A) to the canister. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE G)

5.

Connect the circulate tube (B) to the fuel tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE D)

6.

Connect the fuel filler hose to the fuel filler pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > FUEL FILLER HOSE CONNECTION

7.

Install the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>INSTALLATION

8.

Install the rear exhaust pipe and muffler.

Rear exhaust pipe:

EXHAUST(H4DO)>Rear Exhaust Pipe>INSTALLATION

Muffler:

EXHAUST(H4DO)>Muffler>INSTALLATION

9.

Install the fuel tank protector. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Tank Protector>INSTALLATION

10.

Lower the vehicle.

11.

Connect the connector to the fuel sub level sensor.

 

Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel sub level sensor and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.

12.

Install the service hole cover of fuel sub level sensor.

13.

Connect the connector to the fuel pump.

 

Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel pump and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.

14.

Install the service hole cover of fuel pump.

15.

Install the rear seat cushion. SEATS>Rear Seat>INSTALLATION

16.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Tank　
INSPECTION
1.

Check that the fuel tank and fuel pipe have no deformation, cracks and other damages.

2.

Check that the fuel hose and tube have no cracks, damage or loose part.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Filler Pipe　
REMOVAL
 

Place “NO OPEN FLAMES” signs near the working area.

 

Be careful not to spill fuel.

 

For the removal procedure of fuel filler lid, refer to “Fuel filler lid”. SECURITY AND LOCKS>Remote Openers>REMOVAL > FUEL LID

1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Drain fuel. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > DRAINING FUEL (WITH SUBARU SELECT MONITOR)

3.

Open the fuel filler lid and remove the fuel filler cap.

4.

Turn the fuel filler pipe protector in the direction of the arrow to release the lock (A) and remove it.

5.

Remove the rear sub frame assembly. REAR SUSPENSION>Sub Frame>REMOVAL

6.

Remove the mud guard rear RH. EXTERIOR/INTERIOR TRIM>Mud Guard>REMOVAL

7.

Disconnect the fuel filler hose (A), drain tube (B) and circulate tube (C) from the fuel filler pipe assembly.

Drain tube:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE F)

Circulate tube:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE D)

8.

Remove the drain tube from clip (D).

9.

Remove the bolts which secure the fuel filler pipe assembly.

10.

Remove the nuts which secure the fuel filler pipe assembly, and remove the fuel filler pipe assembly from underneath of the vehicle.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Filler Pipe　
INSTALLATION
 

For the installation procedure of fuel filler lid, refer to “Fuel filler lid”. SECURITY AND LOCKS>Remote Openers>INSTALLATION > FUEL LID

1.

Open the fuel filler lid.

2.

Insert the fuel filler pipe assembly into the ring clip from inside of the rear fender.

3.

Install the nuts securing the fuel filler pipe assembly.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

4.

Install the bolts securing the fuel filler pipe assembly.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

5.

Install the drain tube to clip (D).

6.

Connect the fuel filler hose (A), drain tube (B) and circulate tube (C) to the fuel filler pipe assembly.

Fuel filler hose:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > FUEL FILLER HOSE CONNECTION

Drain tube:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE F)

Circulate tube:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE D)

7.

Install the mud guard rear RH. EXTERIOR/INTERIOR TRIM>Mud Guard>INSTALLATION

8.

Install the rear sub frame assembly. REAR SUSPENSION>Sub Frame>INSTALLATION

9.

Install the fuel filler pipe protector.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Filler Pipe　
DISASSEMBLY
1.

Remove the drain filter. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>Drain Filter>REMOVAL

2.

Disassemble the fuel filler pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>General Description>COMPONENT > FUEL FILLER PIPE

 

Using a marker pen, make alignment marks (a) to use for positioning brackets during assembly.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Filler Pipe　
ASSEMBLY
1.

Using a new neck holder, assemble the fuel filler pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>General Description>COMPONENT > FUEL FILLER PIPE

 

Install the fuel filler pipe bracket to the fuel filler pipe by aligning the alignment marks (a).

2.

Install the drain filter. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>Drain Filter>INSTALLATION

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Filler Pipe　
INSPECTION
1.

Check that the fuel filler pipe assembly has no deformation, cracks or other damages.

2.

Check that the fuel hose has no cracks, damage or loose part.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Pump　
REMOVAL
 

Place “NO OPEN FLAMES” signs near the working area.

 

  • Be careful not to spill fuel.

  • Catch the fuel from the tubes using a container or cloth.

  • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill.

 

Fuel pump assembly consists of fuel pump, fuel filter and fuel level sensor.

1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Drain fuel. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > DRAINING FUEL (WITH SUBARU SELECT MONITOR)

3.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Remove the rear seat cushion. SEATS>Rear Seat>REMOVAL

5.

Remove the service hole cover of fuel pump.

6.

Disconnect the connector from fuel pump.

7.

Disconnect the fuel delivery tube. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE D)

8.

Remove the ring nut using the ST.

 

  • Be careful not to damage the tube with the ST.

  • Before setting the ST, move the tube above the ST.

Preparation tool:

ST: ST FUEL PUMP (42099FL000)

9.

Take out the fuel pump assembly from the fuel tank, and disconnect the fuel sub delivery tube from the fuel pump assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE D)

 

Be careful not to let the arm and float of the fuel level sensor contact the fuel tank.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Pump　
INSTALLATION
1.

Install a new gasket to the fuel tank.

2.

Connect the fuel sub delivery tube to the fuel pump assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE D)

 

Connect so that the rib (a) of fuel pump assembly aligns between the retainers (b) of quick connector.

3.

Set the fuel pump to the position shown in the figure.

 

  • Be careful not to spill any fuel over the gasket. If any fuel is spilled onto the gasket, wipe it off completely. Otherwise the fuel pump may rotate together with the ring nut.

  • Set the arm and float of the fuel level sensor while paying attention to prevent them from contacting the fuel tank. If the arm of the fuel level sensor is bent, the fuel gauge may not read correctly.

(a)

Position mark (fuel pump)

(b)

Fuel pump installation position range mark (fuel tank)

(c)

Front side of vehicle
4.

Set a new ring nut plate.

5.

Set a new ring nut, and align the fuel tank installation start position mark with the ring nut position mark.

 

  • Make sure that the ring nut, ring nut plate and gasket are set as shown in the figure.

  • Set the ring nut by firmly pressing against the fuel tank.

(a)

Installation start position mark (fuel tank)

(c)

Ring nut

(e)

Gasket

(b)

Position mark (ring nut)

(d)

Ring nut plate
6.

Using the ST, tighten the ring nut by one turn, and then tighten until the ring nut position mark is located within the installation end position range mark on the fuel tank.

 

  • Be careful not to damage the tube with the ST.

  • Before setting the ST, move the tube above the ST.

  • Make sure that the ring nut position mark is located within the installation position end range mark on the fuel tank as shown in the figure.

  • Make sure that the position mark on the fuel pump is located within the installation position range mark on the fuel tank as shown in the figure.

Preparation tool:

ST: ST FUEL PUMP (42099FL000)

(a)

Ring nut installation position start mark (fuel tank)

(c)

Ring nut installation position end range mark (fuel tank)

(e)

Position mark (fuel pump)

(b)

Position mark (ring nut)

(d)

Fuel pump installation position range mark (fuel tank)

(f)

Front side of vehicle
7.

Using a caliper with depth gauge, measure the dimension (3 positions) of the ring nut and the top of fuel tank to check the tightening condition of the ring nut.

 

  • If the measured value exceeds the standard, retighten the ring nut to correct erroneous tightening of the ring nut.

  • If the ring nut and ring nut plate are deformed, cracked or damaged, replace them with new parts.

Dimension of ring nut and top of fuel tank:

Standard

23.8±2.5mm (0.937±0.098in)

(A)

Caliper with depth gauge

(C)

Fuel tank

(E)

Measuring point

(B)

Ring nut

(D)

Dimension of ring nut and top of fuel tank

(F)

Front side of vehicle
8.

Connect the fuel delivery tube. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE D)

9.

Connect the connector to the fuel pump.

 

Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel pump and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.

10.

Install the service hole cover of fuel pump.

11.

Install the rear seat cushion. SEATS>Rear Seat>INSTALLATION

12.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Pump　
INSPECTION
1.

Check that the fuel pump has no deformation, cracks or other damages.

2.

Connect the battery positive terminal to terminal No. 5 and the battery ground terminal to terminal No. 6, and inspect the fuel pump operation.

 

  • Wipe off fuel completely.

  • Keep the battery as far apart from fuel pump as possible.

  • Do not run the fuel pump for a long time under non-load condition.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Level Sensor　
REMOVAL
 

Place “NO OPEN FLAMES” signs near the working area.

 

  • Be careful not to spill fuel.

  • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill.

 

The fuel level sensor is built in fuel pump assembly.

1.

Remove the fuel pump assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump>REMOVAL

2.

Disconnect the fuel level sensor connector (A), and pull out the connector cable and fuel level sensor harness from the clip.

3.

While pressing the claw (A) of the fuel level sensor, slide the fuel level sensor in the direction of the arrow, and remove the fuel level sensor.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Level Sensor　
INSTALLATION
1.

Install the fuel level sensor to the fuel pump assembly.

 

Be sure to install the fuel level sensor harness to the clip first, then install the connector cable. Otherwise, malfunction may occur.

(A)

Fuel level sensor harness

(B)

Connector cable
2.

Install the fuel pump assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump>INSTALLATION

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Level Sensor　
INSPECTION
1.

Check that the fuel level sensor has no damage.

2.

Measure the fuel level sensor float position.

 

When inspecting the fuel level sensor, perform the work with the sensor installed to the fuel pump.

(A)

FULL

(B)

EMPTY

(C)

Fuel tank seating surface

Float position

Standard

FULL — Fuel tank seating surface H1

190.7±3.5 mm (7.508±0.138in)

EMPTY — Fuel tank seating surface H2

24.6±3.5 mm (0.969±0.138in)
3.

Check the resistance between fuel level sensor terminals by the connector on top of the fuel pump.

Float position

Terminal No.

Standard

FULL (A)

1 and 4

8.7±1.0 Ω

EMPTY (B)

233.4±2.5 Ω
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Sub Level Sensor　
REMOVAL
 

Place “NO OPEN FLAMES” signs near the working area.

 

  • Be careful not to spill fuel.

  • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill.

1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Drain fuel. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > DRAINING FUEL (WITH SUBARU SELECT MONITOR)

3.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Remove the rear seat cushion. SEATS>Rear Seat>REMOVAL

5.

Remove the service hole cover of fuel sub level sensor.

6.

Disconnect the connector from the fuel sub level sensor.

7.

Remove the ring nut using the ST.

Preparation tool:

ST: ST FUEL PUMP (42099FL000)

8.

Take out the fuel sub level sensor from the fuel tank, and remove the fuel sub delivery tube from the fuel sub level sensor.

 

Be careful not to let the arm and float of the fuel sub level sensor contact the fuel tank during the removal.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Sub Level Sensor　
INSTALLATION
1.

Install a new gasket to the fuel tank.

2.

Install the fuel sub delivery tube to the fuel sub level sensor.

3.

Set the fuel sub level sensor to the position shown in the figure.

 

  • Be careful not to spill any fuel over the gasket. If any fuel is spilled onto the gasket, wipe it off completely. Otherwise the fuel sub level sensor may rotate together with the ring nut.

  • Set the fuel sub level sensor while paying attention to prevent its arm and float from contacting the fuel tank. If the arm of the fuel sub level sensor is bent, the fuel gauge may not read correctly.

(a)

Position mark (fuel sub level sensor)

(b)

Fuel sub level sensor installation position range mark (fuel tank)

(c)

Front side of vehicle
4.

Set a new ring nut plate.

5.

Set a new ring nut, and align the fuel tank installation start position mark with the ring nut position mark.

 

  • Make sure that the ring nut, ring nut plate and gasket are set as shown in the figure.

  • Set the ring nut by firmly pressing against the fuel tank.

(a)

Installation start position mark (fuel tank)

(c)

Ring nut

(e)

Gasket

(b)

Position mark (ring nut)

(d)

Ring nut plate
6.

Using the ST, tighten the ring nut by one turn, and then tighten until the ring nut position mark is located within the installation end position range mark on the fuel tank.

 

  • Make sure that the ring nut position mark is located within the installation position end range mark on the fuel tank as shown in the figure.

  • Make sure that the position mark on the fuel sub level sensor is located within the installation position range mark on the fuel tank as shown in the figure.

Preparation tool:

ST: ST FUEL PUMP (42099FL000)

(a)

Ring nut installation position start mark (fuel tank)

(c)

Ring nut installation position end range mark (fuel tank)

(e)

Position mark (fuel sub level sensor)

(b)

Position mark (ring nut)

(d)

Fuel sub level sensor installation position range mark (fuel tank)

(f)

Front side of vehicle
7.

Using a caliper with depth gauge, measure the dimension (3 positions) of the ring nut and the top of fuel tank to check the tightening condition of the ring nut.

 

  • If the measured value exceeds the standard, retighten the ring nut to correct erroneous tightening of the ring nut.

  • If the ring nut and ring nut plate are deformed, cracked or damaged, replace them with new parts.

Dimension of ring nut and top of fuel tank:

Standard

23.8±2.5mm (0.937±0.098in)

(A)

Caliper with depth gauge

(C)

Fuel tank

(E)

Measuring point

(B)

Ring nut

(D)

Dimension of ring nut and top of fuel tank

(F)

Front side of vehicle
8.

Connect the connector to the fuel sub level sensor.

 

Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel sub level sensor and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.

9.

Install the service hole cover of fuel sub level sensor.

10.

Install the rear seat cushion. SEATS>Rear Seat>INSTALLATION

11.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Sub Level Sensor　
INSPECTION
1.

Check that the fuel sub level sensor has no damage.

2.

Check the fuel sub level sensor float position.

(A)

FULL

(B)

EMPTY

(C)

Fuel sub level sensor seating surface

Float position

Standard

FULL — Fuel sub level sensor seating surface H1

145.1±4.5 mm (5.713±0.177in)

EMPTY — Fuel sub level sensor seating surface H2

14.6±4.5 mm (0.575±0.177in)
3.

Check the resistance between fuel sub level sensor terminals by the connector on top of the fuel sub level sensor.

Float position

Terminal No.

Standard

FULL (A)

1 and 2

8.7±1.0 Ω

EMPTY (B)

176.6±2.0 Ω
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Filter　
REMOVAL
 

Place “NO OPEN FLAMES” signs near the working area.

 

  • Be careful not to spill fuel.

  • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill.

  • Be careful not to drop or apply any impact to the fuel pump during work. This may deteriorate its performance.

 

The fuel filter is built in fuel pump assembly.

1.

Remove the fuel pump assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump>REMOVAL

2.

Remove the fuel level sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Level Sensor>REMOVAL

3.

Disconnect the connector cable.

4.

Push the fuel filter assembly in the direction of the arrow to compress, and detach the connecting clip.

5.

Release the claw using a flat tip screwdriver or similar tool wrapped with a protection tape, and remove the tube assembly from the fuel chamber assembly.

6.

Disengage three claws on the fuel pump holder from the fuel chamber assembly, and remove the fuel filter assembly.

7.

Remove the tube assembly from the fuel chamber assembly.

8.

Remove the O-ring from the fuel chamber assembly.

9.

Remove the fuel pump holder.

10.

Disengage three claws on the fuel pump.

11.

Using a flat tip screwdriver or similar tool wrapped with a protection tape, press on the fuel pump and remove the fuel pump from the fuel filter assembly.

 

If O-rings remain on the fuel filter assembly side, they must be carefully removed using a precision screwdriver or similar tool wrapped with a protection tape.

12.

Remove the spacer (A) and connector cable (B) from the fuel pump.

13.

Remove the pressure regulator cap.

14.

Remove the pressure regulator from the fuel filter assembly.

15.

Remove O-ring (A), O-ring (B), and backup ring (C) from the pressure regulator.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Filter　
INSTALLATION
1.

Install backup ring (C), new O-ring (B) and new O-ring (A) to the pressure regulator.

 

Apply gasoline to the O-ring and backup ring.

2.

Install the pressure regulator to the fuel filter assembly.

3.

Install the pressure regulator cap.

 

After installation, make sure 3 claws are securely engaged in each position.

4.

Install new connector cable (C), spacer (B) and new O-ring (A) to the fuel pump.

 

Apply gasoline to the O-rings and the spacer.

5.

Install the fuel pump to the fuel filter assembly.

 

After installation, make sure 3 claws are securely engaged in each position.

6.

Install the fuel pump holder.

7.

Install a new O-ring to the fuel chamber assembly.

 

Apply gasoline to the O-ring.

8.

Install the tube assembly to the fuel chamber assembly.

9.

Install the fuel filter assembly to the fuel chamber assembly.

 

  • Set the spring (b) and tube (a) for the fuel filter assembly as shown in the figure.

  • Check that the claws fastening the fuel camber assembly and the fuel filter assembly are securely engaged.

10.

Connect the tube assembly to the fuel chamber assembly.

11.

Push the fuel filter assembly in the direction of the arrow to compress, and attach the new clip.

12.

Connect the connector cable.

13.

Install the fuel level sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Level Sensor>INSTALLATION

14.

Inspect the fuel level sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Level Sensor>INSPECTION

15.

Install the fuel pump assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump>INSTALLATION

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Delivery and Evaporation Lines　
REMOVAL
 

Place “NO OPEN FLAMES” signs near the working area.

 

Be careful not to spill fuel.

1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Drain fuel. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > DRAINING FUEL (WITH SUBARU SELECT MONITOR)

3.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Open the fuel filler lid and remove the fuel filler cap.

 

This operation is required to release the inner pressure of the fuel tank.

5.

Remove the fuel delivery tube clamp from the fuel delivery tube.

6.

Disconnect the quick connector on the fuel delivery tube from the fuel pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE A)

7.

Disconnect the evaporation hose from the fuel pipe assembly.

8.

Remove the connector from the fuel pipe bracket A.

9.

Lift up the vehicle.

10.

Remove the bolts securing the fuel bracket A, and remove the pipe clamp from the fuel pipe assembly.

11.

Remove the fuel tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Tank>REMOVAL

12.

Remove the hoses and tubes from the fuel tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>General Description>COMPONENT > FUEL TANK 1

13.

Disconnect the purge tube from the fuel pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE E)

14.

Remove the under cover rear RH. EXTERIOR/INTERIOR TRIM>Floor Under Protector>REMOVAL

15.

Disconnect the brake pipe. BRAKE>Brake Hose>REMOVAL > REAR BRAKE HOSE BRAKE>Brake Pipe>REMOVAL > CENTER BRAKE PIPE

16.

Remove the bolts securing the fuel pipe bracket B and the fuel pipe bracket C, and remove the pipe clamp from the fuel pipe assembly.

17.

Remove the fuel pipe assembly.

18.

Remove the fuel sub delivery tube.

(1)

Remove the fuel pump. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump>REMOVAL

(2)

Remove the fuel sub level sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Sub Level Sensor>REMOVAL

(3)

Remove the fuel sub delivery tube from the fuel tank.

1. QUICK CONNECTOR DISCONNECTION (TYPE A)
 

  • Be careful not to spill fuel.

  • Catch the fuel from the tubes using a container or cloth.

Disconnect the quick connector as shown in the figure.

(a)

Slider
2. QUICK CONNECTOR DISCONNECTION (TYPE B)
 

  • Be careful not to spill fuel.

  • Catch the fuel from the tubes using a container or cloth.

Disconnect the quick connector as shown in the figure.

(a)

Slider
3. QUICK CONNECTOR DISCONNECTION (TYPE C)
 

  • Be careful not to spill fuel.

  • Catch the fuel from the tubes using a container or cloth.

Disconnect the quick connector as shown in the figure.

(a)

Slider

4. QUICK CONNECTOR DISCONNECTION (TYPE D)

  • When using ST

    1. Attach the ST to the pipe and push the ST in the direction of arrow mark to disconnect the quick connector.

      Preparation tool:

      ST: QUICK CONNECTOR RELEASE (42099AE000)

       

      • Be careful not to spill fuel.

      • Catch the fuel from hoses using a container or cloth.

      • Holding the portion (c) shown in the figure, pull the connector in axial direction.

      • If the connector and pipe are sticking to each other, push and pull the connector with the ST pushed, and then pull the connector after it starts moving freely.

      • When disconnecting the connector, do not bend or twist the tube forcibly. If the tube is bent, replace it with a new part.

       

      Clean the pipe and quick connector, if they are covered with dust.

      (a)

      Quick connector

      (b)

      Pipe

      (c)

      Connector holding position

    2. To prevent from damaging or entering foreign matter, wrap the pipes and quick connectors with plastic bag etc.

       

      When reusing the retainer, do not disconnect the retainer from the connector.

  • When not using ST

    1. Push the retainer in the direction of the arrow, disconnect the quick connector from pipe.

       

      • Be careful not to spill fuel.

      • Catch the fuel from hoses using a container or cloth.

      • Holding the portion (d) shown in the figure, pull the connector in axial direction.

      • If the connector and pipe are sticking to each other, push and pull the connector with the retainer pushed in the direction of the arrow, and then pull the connector after it starts moving freely.

      • When disconnecting the connector, do not bend or twist the tube forcibly. If the tube is bent, replace it with a new part.

       

      Clean the pipe and quick connector, if they are covered with dust.

      (a)

      Quick connector

      (c)

      Pipe

      (d)

      Connector holding position

      (b)

      Retainer

    2. To prevent from damaging or entering foreign matter, wrap the pipes and quick connectors with plastic bag etc.

       

      When reusing the retainer, do not disconnect the retainer from the pipe.

5. QUICK CONNECTOR DISCONNECTION (TYPE E)

Disconnect the quick connector as shown in the figure.

6. QUICK CONNECTOR DISCONNECTION (TYPE F)

Disconnect the quick connector as shown in the figure.

7. QUICK CONNECTOR DISCONNECTION (TYPE G)

Disconnect the quick connector as shown in the figure.

(a)

Slider

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Delivery and Evaporation Lines　
INSTALLATION
1.

Install the fuel sub delivery tube.

(1)

Set the fuel sub delivery tube to the fuel tank.

 

  • Route the fuel sub delivery tube in front of the stand-off as shown in the figure.

  • Check the fuel sub delivery tube to make sure it’s not twisted.

(A)

Stand-off

(B)

Fuel sub delivery tube
(2)

Install the fuel sub level sensor. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Sub Level Sensor>INSTALLATION

(3)

Install the fuel pump. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump>INSTALLATION

2.

Install the fuel pipe assembly.

3.

Install the pipe clamp to the fuel pipe assembly, and then install the fuel pipe bracket B and fuel pipe bracket C.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

4.

Connect the brake pipes. BRAKE>Brake Hose>INSTALLATION > REAR BRAKE HOSE BRAKE>Brake Pipe>INSTALLATION > CENTER BRAKE PIPE

5.

Install the under cover rear RH. EXTERIOR/INTERIOR TRIM>Floor Under Protector>INSTALLATION

6.

Connect the purge tube to the fuel pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE E)

7.

Connect individual hoses and tubes to the fuel tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>General Description>COMPONENT > FUEL TANK 1

8.

Install the fuel tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Tank>INSTALLATION

9.

Install the pipe clamp to the fuel pipe assembly, and then install the fuel pipe bracket A.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

10.

Lower the vehicle.

11.

Install the connector to the fuel pipe bracket A.

12.

Connect the evaporation hose to fuel pipe assembly.

13.

Connect the quick connector on the fuel delivery tube to the fuel pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE A)

14.

Install the fuel delivery tube clamp to the fuel delivery tube.

1. QUICK CONNECTOR CONNECTION (TYPE A)
 

  • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

  • When connecting the quick connector, make sure to insert it all the way in before locking the slider.

  • When it is difficult to lock the slider, check that the connector is fully inserted.

  • After locking the slider, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

 

Connect the quick connector as shown in the figure.

(a)

Slider
2. QUICK CONNECTOR CONNECTION (TYPE B)
 

  • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

  • When connecting the quick connector, make sure to insert it all the way in before locking the slider.

  • When it is difficult to lock the slider, check that the connector is fully inserted.

  • After locking the slider, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

 

Connect the quick connector as shown in the figure.

(a)

Slider
3. QUICK CONNECTOR CONNECTION (TYPE C)
 

  • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

  • When connecting the quick connector, make sure to insert it all the way in before locking the slider.

  • When it is difficult to lock the slider, check that the connector is fully inserted.

  • After locking the slider, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

 

Connect the quick connector as shown in the figure.

(a)

Slider
4. QUICK CONNECTOR CONNECTION (TYPE D)
 

  • Make sure there are no damage or dust on connections. If necessary, clean seal surface of pipe.

    (a)

    When removed using the ST

    (c)

    Seal surface

    (d)

    Pipe

    (b)

    When removed without using the ST

  • When reusing the retainer, make sure that neither scratches nor deformation exist on the retainer. If it is faulty, use a new part.

Connect the quick connector.

 

  • After connecting the quick connector, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

    (a)

    Quick connector

    (b)

    Retainer

    (c)

    Pipe

  • Make sure the two retainer pawls are engaged in their mating positions in the quick connector.

  • Be sure to inspect tubes and their connections for any leakage of fuel.

  • Holding the portion (f) shown in the figure, push in the connector in axial direction.

  • When connecting the connector, do not bend or twist the tube forcibly. If the tube is bent, replace it with a new part.

(a)

When removed using the ST

(c)

Quick connector

(e)

Pipe

(b)

When removed without using the ST

(d)

Retainer

(f)

Connector holding position
5. QUICK CONNECTOR CONNECTION (TYPE E)
 

  • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

  • After connecting the quick connector, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

 

Connect the quick connector as shown in the figure.

6. QUICK CONNECTOR CONNECTION (TYPE F)
 

  • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

  • After connecting the quick connector, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

 

Connect the quick connector as shown in the figure.

7. QUICK CONNECTOR CONNECTION (TYPE G)
 

  • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

  • When connecting the quick connector, make sure to insert it all the way in before locking the slider.

  • When it is difficult to lock the slider, check that the connector is fully inserted.

  • After locking the slider, pull the quick connector body in the removal direction and then push it in the connecting direction, in order to check that the quick connector is securely connected. Always make sure to perform this confirmation ending up with a pushing in.

 

Connect the quick connector as shown in the figure.

(a)

Slider
8. EVAPORATION HOSE CONNECTION

Connect by inserting it to the pipe until it reaches the spool or bump.

(a)

Hose

(c)

Spool or bump

(d)

Pipe

(b)

Clip
9. FUEL FILLER HOSE CONNECTION

Securely insert the hose to the spool, and then install the clamp as shown in the figure.

Tightening torque:

2.5N·m (0.3kgf-m, 1.8ft-lb)

(a)

Fuel filler hose

(c)

Spool

(d)

Fuel filler pipe

(b)

Clamp
FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Fuel Delivery and Evaporation Lines　
INSPECTION
1.

Check that the fuel pipe has no deformation, cracks or other damages.

2.

Check that the hose and tube have no cracks, damage or loose part.

FUEL INJECTION (FUEL SYSTEMS)(H4DO) > Symptoms and causes　
INSPECTION

Symptoms

Problem parts etc.

Possible cause

Insufficient fuel supply

Fuel pump fuse

Blown-out fuse

Fuel pump relay

Faulty relay operation

Fuel pump

Faulty pump operation

Poor contact of connector

Fuel filter

Clogging of filter

Fuel injector

Clogging or malfunction of fuel injector

Fuel line pipe, hose or tube

Clogging or deformation of pipe, hose or tube

Pressure regulator

Seized or damaged diaphragm

Air in the fuel system

Fuel percolation or excessive fuel shortage in tank

Fuel leakage

Fuel pump assembly

Defective gasket or improper installation of fuel pump assembly

Fuel sub level sensor

Defective gasket or improper installation

Fuel line pipe, hose and tube

Hole, cracking or improper installation of pipe, hose or tube

Fuel tank

Hole, cracking in tank

Gasoline smell inside of compartment

Fuel line pipe, hose and tube

Hole, cracking or improper installation of pipe, hose or tube

Service hole cover

Deformed cover, defective gasket or improper installation

 

Check that no fuel leakage occurs.

Saucer COMPL

Damage or improper installation of saucer

Defective fuel gauge display

Fuel level sensor or fuel sub level sensor

Poor contact at resistance part

Seized or deformed arm

Deformed or damaged float

Connector connection is improper.

Combination meter

Defective combination meter

Noise

Fuel pump

Defective pump or improper installation
 

  • Water generated in the fuel tank may be frozen at cold condition.

    It is preferable to keep the tank full with fuel if possible and to use a water removing agent or anti-freeze agent, etc. if necessary.

  • If a water removing agent or anti-freeze agent, etc. is used, follow the instruction for use.