Subaru 2001 Forester User manual

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

FUEL INJECTION (FUEL SYSTEMS)
FU(DOHC TURBO)
Page
1. General Description.....................................................................................2
2. Throttle Body.............................................................................................14
3. Intake Manifold..........................................................................................15
4. Engine Coolant Temperature Sensor........................................................29
5. Crankshaft Position Sensor.......................................................................30
6. Camshaft Position Sensor.........................................................................31
7. Knock Sensor............................................................................................32
8. Throttle Position Sensor............................................................................33
9. Mass Air Flow and Intake Air Temperature Sensor..................................34
10. Pressure Sensor........................................................................................35
11. Idle Air Control Solenoid Valve .................................................................36
12. Fuel Injector...............................................................................................37
13. Tumble Generator Valve Assembly...........................................................40
14. Wastegate Control Solenoid Valve............................................................41
15. Front Oxygen (A/F) Sensor.......................................................................42
16. Rear Oxygen Sensor.................................................................................44
17. Exhaust Temperature Sensor....................................................................46
18. Engine Control Module..............................................................................47
19. Main Relay ................................................................................................48
20. Fuel Pump Relay.......................................................................................49
21. Fuel............................................................................................................50
22. Fuel Tank...................................................................................................53
23. Fuel Filler Pipe..........................................................................................56
24. Fuel Pump.................................................................................................60
25. Fuel Level Sensor.....................................................................................62
26. Fuel Sub Level Sensor..............................................................................63
27. Fuel Filter ..................................................................................................64
28. Fuel Cut Valve...........................................................................................65
29. Fuel Damper Valve....................................................................................66
30. Fuel Delivery, Return and Evaporation Lines ...........................................67
31. Fuel System Trouble in General...............................................................70

1. General Description S185001
A: SPECIFICATIONS S185001E49
Model
Fuel tank Capacity 60 (15.9 US gal, 13.2 Imp gal)
Location Under rear seat
Fuel pump
Type Impeller
Shutoff discharge pressure 450 —677 kPa (4.59 —6.9 kg/cm
2
, 65.27 —98.2 psi)
Discharge flow More than 130 (34.3 US gal, 28.6 Imp gal)/h
[12 V at 300 kPa (3.06 kg/cm
2
, 43.5 psi)]
Fuel filter Cartridge type
FU(DOHC TURBO)-2
GENERAL DESCRIPTION
Fuel Injection (Fuel Systems)

MEMO:
FU(DOHC TURBO)-3
GENERAL DESCRIPTION Fuel Injection (Fuel Systems)

B: COMPONENT S185001A05
1. INTAKE MANIFOLD S185001A0501
S2M2173A
FU(DOHC TURBO)-4
GENERAL DESCRIPTION
Fuel Injection (Fuel Systems)

(1) Fuel pipe ASSY
(2) Fuel hose
(3) Clip
(4) Purge control solenoid valve
(5) Vacuum hose
(6) Vacuum control hose
(7) Purge valve
(8) Purge hose
(9) Intake manifold gasket
(10) Guide pin
(11) Tumble generator valve ASSY
(12) Tumble generator valve gasket
(13) Accelerator cable bracket
(14) Fuel injector
(15) Insulator
(16) Fuel injector pipe
(17) Pressure regulator
(18) Pressure regulator hose
(19) Blow-by hose stay
(20) Intake manifold
(21) Wastegate control solenoid valve
ASSY
(22) Nipple
(23) Fuel pipe protector
Tightening torque: N·m (kgf-m, ft-lb)
T1: 5 (0.50, 3.7)
T2: 6.4 (0.65, 4.7)
T3: 8.25 (0.84, 6.1)
T4: 16 (1.63, 11.8)
T5: 17 (1.73, 12.5)
T6: 19 (1.94, 14.0)
T7: 25 (2.55, 18.4)
FU(DOHC TURBO)-5
GENERAL DESCRIPTION Fuel Injection (Fuel Systems)

2. AIR INTAKE SYSTEM S185001A0502
EN0779
(1) Gasket
(2) Throttle position sensor
(3) Idle air control solenoid valve
(4) Throttle body
(5) Pressure sensor Tightening torque: N·m (kgf-m, ft-lb)
T1: 1.6 (0.16, 1.2)
T2: 2.8 (0.29, 2.1)
T3: 22 (2.2, 16)
FU(DOHC TURBO)-6
GENERAL DESCRIPTION
Fuel Injection (Fuel Systems)

3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS S185001A0503
EN0780
(1) Crankshaft position sensor
(2) Knock sensor
(3) Camshaft position sensor
Tightening torque: N·m (kgf-m, ft-lb)
T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU(DOHC TURBO)-7
GENERAL DESCRIPTION Fuel Injection (Fuel Systems)

4. FUEL TANK S185001A0504
S2M2152A
FU(DOHC TURBO)-8
GENERAL DESCRIPTION
Fuel Injection (Fuel Systems)

(1) Heat sealed cover
(2) Fuel tank band
(3) Protector LH
(4) Protector RH
(5) Fuel tank
(6) Fuel pump gasket
(7) Fuel pump ASSY
(8) Fuel level snsor
(9) Fuel cut valve gasket
(10) Fuel cut valve
(11) Evaporation hose A
(12) Clip
(13) Evaporation hose B
(14) Joint pipe
(15) Evaporation hose C
(16) Evaporation pipe ASSY
(17) Evaporation hose D
(18) Evaporation hose E
(19) Fuel return hose A
(20) Retainer
(21) Quick connector
(22) Evaporation hose F
(23) Fuel pipe ASSY
(24) Evaporation hose G
(25) Fuel return hose B
(26) Fuel sub level sensor gasket
(27) Jet pump filter
(28) Fuel sub level sensor
(29) Evaporation hose H
(30) Evaporation hose I
Tightening torque: N·m (kgf-m, ft-lb)
T1: 4.4 (0.45, 3.3)
T2: 7.4 (0.75, 5.4)
T3: 33 (3.4, 25)
FU(DOHC TURBO)-9
GENERAL DESCRIPTION Fuel Injection (Fuel Systems)

5. FUEL LINE S185001A0505
S2M2153A
FU(DOHC TURBO)-10
GENERAL DESCRIPTION
Fuel Injection (Fuel Systems)

(1) Clip
(2) Fuel delivery hose A
(3) Fuel filter bracket
(4) Fuel filter holder
(5) Fuel filter cup
(6) Fuel filter
(7) Evaporation hose A
(8) Fuel damper
(9) Fuel delivery hose B
(10) Fuel return hose
(11) Fuel pipe ASSY
(12) Grommet
(13) Canister hose A
(14) Canister
(15) Canister bracket plate
(16) Cushion
(17) Canister bracket spacer
(18) Rear canister bracket
(19) Two-way valve return hose
(20) Two-way valve
(21) Two-way valve drain hose A
(22) Connector
(23) Two-way valve drain hose B
(24) Clamp
(25) Front canister bracket
(26) Evaporation hose B
(27) Roll over valve bracket
(28) Roll over valve
(29) Evaporation hose C
(30) Evaporation pipe
(31) Canister hose B
Tightening torque: N·m (kgf-m, ft-lb)
T1: 23 (2.34, 17.0)
FU(DOHC TURBO)-11
GENERAL DESCRIPTION Fuel Injection (Fuel Systems)

6. FUEL FILLER PIPE S185001A0506
S2M2245A
(1) Fuel filter pipe ASSY
(2) Evaporation hose holder
(3) Clamp
(4) Clamp
(5) Air vent hose
(6) Air vent pipe
(7) Air vent pipe holder
(8) Filler pipe packing
(9) Filler ring
(10) Filler cap
(11) Fuel pipe protector
Tightening torque: N·m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.5)
FU(DOHC TURBO)-12
GENERAL DESCRIPTION
Fuel Injection (Fuel Systems)

C: CAUTION S185001A03
쐌Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
쐌Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
쐌Keep the disassembled parts in order and pro-
tect them from dust or dirt.
쐌Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary
removal, installation, disassembly, and replace-
ment.
쐌Be careful not to burn your hands, because each
part on the vehicle is hot after running.
쐌Be sure to tighten fasteners including bolts and
nuts to the specified torque.
쐌Place shop jacks or safety stands at the speci-
fied points.
쐌Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.
쐌Place “NO FIRE”signs near the working area.
쐌Be careful not to spill fuel on the floor.
D: PREPARATION TOOL S185001A17
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B2M3876
24082AA150
(Newly adopted tool) CARTRIDGE Troubleshooting for electrical system.
B2M3877
22771AA030 SELECT MONITOR
KIT Troubleshooting for electrical systems. 쐌English: 22771AA030 (Without printer)
쐌German: 22771AA070 (Without printer)
쐌French: 22771AA080 (Without printer)
쐌Spanish: 22771AA090 (Without printer)
FU(DOHC TURBO)-13
GENERAL DESCRIPTION Fuel Injection (Fuel Systems)

2. Throttle Body S185010
A: REMOVAL S185010A18
1) Disconnect battery ground cable.
G6M0095
2) Remove intercooler. <Ref. to IN(DOHC
TURBO)-10, REMOVAL, Intercooler.>
3) Disconnect connector from throttle position
sensor (A) and idle air control solenoid valve (B)
and pressure sensor (C).
EN0782
4) Disconnect accelerator cable.
H2M1890
5) Disconnect engine coolant hoses from throttle
body.
EN0784
6) Remove bolts which secure throttle body to
intake manifold.
B: INSTALLATION S185010A11
Install in the reverse order of removal.
NOTE:
Always use new gaskets.
Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)
EN0785
FU(DOHC TURBO)-14
THROTTLE BODY
Fuel Injection (Fuel Systems)

3. Intake Manifold S185034
A: REMOVAL S185034A18
1) Release fuel pressure. <Ref. to FU(DOHC
TURBO)-50, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
2) Disconnect battery ground cable.
G6M0095
3) Lift up vehicle.
4) Remove under cover.
5) Drain coolant about 3.0 (3.2 US qt, 2.6 Imp
qt).
EN0073
6) Remove air cleaner upper cover and air intake
boot. <Ref. to IN(DOHC TURBO)-7, REMOVAL,
Air Cleaner.>
7) Remove air cleaner element.
8) Remove intercooler. <Ref. to IN(DOHC
TURBO)-10, REMOVAL, Intercooler.>
9) Disconnect accelerator cable.
H2M1890
10) Remove coolant filler tank. <Ref. to CO-37,
REMOVAL, Coolant Filler Tank.>
11) Remove power steering pump from bracket.
(1) Remove front side V-belt. <Ref. to
ME(DOHC TURBO)-44, REMOVAL, V-belt.>
(2) Disconnect the power steering switch con-
nector.
EN0360
(3) Remove bolts which secure power steering
pipe brackets to intake manifold.
NOTE:
Do not disconnect power steering hose.
S2M2248
(4) Remove bolts which secure power steering
pump.
H2M1954
FU(DOHC TURBO)-15
INTAKE MANIFOLD Fuel Injection (Fuel Systems)

(5) Remove power steering tank from the
bracket by pulling it upward.
EN0361
(6) Place power steering pump on the right side
wheel apron.
EN0208
12) Disconnect emission hose from PCV valve.
EN0789
13) Disconnect engine coolant hoses from throttle
body.
EN0784
14) Disconnect brake booster hose.
EN0204
15) Disconnect Pressure hose from intake duct.
EN0787
16) Disconnect engine harness connectors from
bulkhead harness connectors.
EN0788
S2M2260
FU(DOHC TURBO)-16
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)

17) Disconnect connectors from engine coolant
temperature sensor (A), oil pressure switch (B) and
crankshaft position sensor (C).
EN0790
18) Disconnect knock sensor connector.
S2M1613
19) Disconnect connector from camshaft position
sensor.
B2M1251
20) Disconnect connector from ignition coil.
EN0854
21) Remove harness secured by clip (A) from the
bracket.
S2M2256A
22) Disconnect fuel delivery hose, return hose and
evaporation hose.
WARNING:
Catch fuel from hoses in a container.
EN0214
23) Remove bolts which secure intake manifold to
cylinder heads.
EN0792
24) Remove intake manifold.
B: INSTALLATION S185034A11
1) Install intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
FU(DOHC TURBO)-17
INTAKE MANIFOLD Fuel Injection (Fuel Systems)

Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
EN0792
2) Connect fuel delivery hose, return hose, and
evaporation hose.
EN0214
3) Connect connector to oil pressure switch (B),
crankshaft position sensor (C) and engine coolant
temperature sensor (A).
EN0790
4) Connect connector to knock sensor.
S2M1613
5) Connect connector to camshaft position sensor.
B2M1251
6) Connect connector to ignition coil.
EN0854
7) Secure harness to the bracket with clip (A).
S2M2256A
FU(DOHC TURBO)-18
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)

8) Connect engine harness connector to bulkhead
harness connectors.
EN0788
S2M2260
9) Connect brake booster vacuum hose.
EN0204
10) Connect engine coolant hoses to throttle body.
EN0784
11) Connect emission hose to PCV valve.
EN0789
12) Connect pressure hose to intake duct.
EN0787
13) Install power steering pump on bracket.
(1) Install power steering tank on bracket.
EN0361
(2) Connect connector to power steering pump
switch.
EN0360
FU(DOHC TURBO)-19
INTAKE MANIFOLD Fuel Injection (Fuel Systems)