General Description

FUEL INJECTION (FUEL SYSTEMS)

1. General Description
A: SPECIFICATION
Capacity 64 2 (16.9 US gal, 14.1 Imp gal)
Fuel tank
Install locations Under rear seat
Type Impeller
Shutoff discharge pressure 550 — 850 kPa (5.61 — 8.67 kg/cm2, 79.8 — 123.3 psi)
Fuel pump
155 2 (41 US gal, 34.1 Imp gal)/h or more
Discharge rate
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter In-tank type

FU(H6DO)-2
 General Description
FUEL INJECTION (FUEL SYSTEMS)

B: COMPONENT
1. INTAKE MANIFOLD

T4
T2
(16)
T3
(9)

T4 (18)

(17)

T5 T4 T5 (15)
T2
(7)
(5) (6)
T4
(17)
T3

(10)
(8)

(3)
T4

(1)
(2)

T2
(11)

(4)
(14) (2)
(13)
(14) T4

T1 T2
T2
T2

T2 (14)
(13)
(14)

T2
(12) T1

FU-04042

FU(H6DO)-3
 General Description
FUEL INJECTION (FUEL SYSTEMS)

(1) Intake manifold (10) Nipple (18) EGR pipe

(2) O-ring (11) Fuel pipe protector LH
(3) Manifold absolute pressure sensor (12) Fuel pipe ASSY Tightening torque:N·m (kgf-m, ft-lb)
(4) Filter (13) Hose T1: 1.25 (0.1, 0.9)
(5) Fuel pipe protector RH (14) Clamp T2: 6.4 (0.7, 4.7)
(6) Purge control solenoid valve (15) EGR valve T3: 17 (1.7, 12.5)
(7) Hose (16) Gasket T4: 19 (1.9, 14.0)
(8) Hose (17) Gasket T5: 25 (2.5, 18.4)
(9) Plug

2. FUEL INJECTOR

(6)

(5)

(4)

(3) T

(2) (1)

(5)
(4)
(3)
(2)
FU-02561

(1) Fuel injector pipe LH (4) Injection rubber Tightening torque:N·m (kgf-m, ft-lb)
(2) Insulator (5) O-ring T: 19 (1.9, 14.0)
(3) Fuel injector (6) Fuel injector pipe RH

FU(H6DO)-4
 General Description
FUEL INJECTION (FUEL SYSTEMS)

3. AIR INTAKE SYSTEM

(2)

(1)

FU-02109

(1) O-ring (2) Throttle body Tightening torque:N·m (kgf-m, ft-lb)

T: 8 (0.8, 5.9)

FU(H6DO)-5
 General Description
FUEL INJECTION (FUEL SYSTEMS)

4. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS

T4

T4
(2)
T1

T2 (3)
(4) T1

(6)
(1)

T1

(5)

T3 (8)

(7)

T2

FU-02110

(1) Crankshaft position sensor (6) Variable valve lift diagnosis oil Tightening torque:N·m (kgf-m, ft-lb)
(2) Knock sensor RH pressure switch RH T1: 6.4 (0.7, 4.7)
(3) Knock sensor LH (7) Variable valve lift diagnosis oil T2: 17 (1.7, 12.5)
(4) Camshaft position sensor RH pressure switch LH T3: 22 (2.2, 16.2)
(5) Camshaft position sensor LH (8) Oil temperature sensor T4: 25 (2.5, 18.4)

FU(H6DO)-6
 General Description
FUEL INJECTION (FUEL SYSTEMS)

5. FUEL TANK
(27)
T1

(28)

(16) (16) (26)

(14)

(7) (15)
(16)
(16)
(6)
(13) (17)
T1
(9)
(16)

(32)
(8) (14)

(16) (25)
(24)

(1)

(16) (30) (11)

(29)
(10)

(31)
T4 (12)

(18)
(3)
(2) T4
(19) (20)
T4

T3 (5)

T3 (20)
T3
T3
(21)

(22)
(23) (4)

T3

T2 T3
T2
FU-04000

FU(H6DO)-7
 General Description
FUEL INJECTION (FUEL SYSTEMS)

(1) Fuel tank (14) Clamp (27) Evaporation hose D

(2) Fuel tank band RH (15) Evaporation hose A (28) Evaporation pipe
(3) Fuel tank band LH (16) Clip (29) Evaporation hose E
(4) Delivery tube (17) Fuel tank protector LH (Rear) (30) Evaporation hose F
(5) Jet pump tube (18) Stopper RH (31) Fuel sub level sensor filter
(6) Fuel pump ASSY (19) Stopper LH (32) Fuel sub level sensor protector
(7) Fuel pump upper plate (20) Retainer
(8) Fuel pump gasket (21) Heat shield cover Tightening torque:N·m (kgf-m, ft-lb)
(9) Fuel level sensor (22) Fuel tank protector RH (Front) T1: 4.4 (0.4, 3.2)
(10) Fuel sub level sensor (23) Fuel tank protector LH (Front) T2: 9 (0.9, 6.6)
(11) Fuel sub level sensor upper plate (24) Evaporation hose B T3: 17.5 (1.8, 12.9)
(12) Fuel sub level sensor gasket (25) Connector T4: 33 (3.4, 24.3)
(13) Fuel filler hose (26) Evaporation hose C

FU(H6DO)-8
 General Description
FUEL INJECTION (FUEL SYSTEMS)

6. FUEL LINE

T4
(5) (6) (7)

(8) (4) T3
T3
T1 (10) (12)
(1) (4)
(4) (4)

(9) (11)
(2)
(4) (4) (13)
T1
(14)
T4
T4

(3) (4)
C
T4

(20) T4
(19)
T4 (15)

(16)
T4
(17)
(29)
(4) (21)
(4) (4)
(27) (23) (22)
(28)
(18)
(4)
(24)
(4) C

(4)
A (26) (25)

T5
T6
T2

(39) B

(40)

(39) (41)
A
T4 (42)
T4

(38)
B (4)
(35) (36)
(39) (30)
(34)
(33)

(4) (37)
(32) (31)

(43)

FU-03217

FU(H6DO)-9
 General Description
FUEL INJECTION (FUEL SYSTEMS)

(1) Evaporation pipe protector (18) Canister (35) Fuel delivery hose A
(2) Evaporation hose D (19) Fuel filler pipe (36) Fuel delivery hose B
(3) Evaporation pipe B (20) Fuel tank pressure sensor (37) Clamp
(4) Clip (21) Canister hose B (38) Quick connector check cover
(5) Fuel filler cap (22) Connector B (39) Clip
(6) Filler ring (23) Pressure control solenoid valve (40) Fuel damper
(7) Shut valve (24) Canister hose A (41) Fuel damper holder
(8) Gasket (25) Connector B (42) Fuel damper bracket
(9) Evaporation hose C (26) Connector A (43) Evaporation hose A
(10) Evaporation hose C (27) Evaporation hose E
(11) Evaporation pipe A (28) Evaporation tube Tightening torque:N·m (kgf-m, ft-lb)
(12) Drain hose connector (29) Retainer T1: 1 (0.1, 0.7)
(13) Drain hose (30) Purge pipe T2: 1.25 (0.1, 0.9)
(14) Connector A (31) Purge hose C T3: 4.4 (0.4, 3.2)
(15) Canister protector (32) Fuel hose T4: 7.5 (0.8, 5.5)
(16) Drain filter (33) Connector T5: 8 (0.8, 5.9)
(17) Drain valve (34) Fuel pipe ASSY T6: 17.6 (1.8, 13.0)

FU(H6DO)-10
 General Description
FUEL INJECTION (FUEL SYSTEMS)

7. FUEL PUMP

(1)

(2)
b (4)
a
b
(5) (2)
d C

(3) (5)

(6)

(2)

(8) C
(7)
d
(10)

(9)

(12)

(13) (11)
FU-04005

(1) Sub tank bracket ASSY (6) Fuel filter (10) Sub tank
(2) O-ring (7) Clip (11) Cushion
(3) O-ring (8) Spacer (12) Fuel level sensor
(4) Fuel pump harness (9) Pump ASSY (13) Fuel temperature sensor
(5) Spring

FU(H6DO)-11
 General Description
FUEL INJECTION (FUEL SYSTEMS)

C: CAUTION
• Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing
any work.
• Remove contamination including dirt and corrosion before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust and dirt.
• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, in-
stallation, disassembly and replacement.
• Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
• Be sure to tighten fasteners including bolts and nuts to the specified torque.
• Place shop jacks or rigid racks at the specified points.
• Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the bat-
tery.
• Place “NO OPEN FLAMES” signs near the working area.
• Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be
spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for envi-
ronmental protection.
• Follow all government and local regulations concerning disposal of refuse when disposing fuel.
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
42099AE000 QUICK Used for disconnecting quick connector of the
CONNECTOR engine compartment.
RELEASE

ST42099AE000
18471AA000 FUEL PIPE Used for draining fuel.
ADAPTER

ST18471AA000
1B022XU0 SUBARU SELECT Used for draining fuel.
MONITOR III KIT

ST1B022XU0

FU(H6DO)-12
 Throttle Body
FUEL INJECTION (FUEL SYSTEMS)

2. Throttle Body
A: REMOVAL
1) Remove the collector cover.
2) Disconnect the ground cable from battery.

IN-00203

3) Remove the air intake chamber. <Ref. to

IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
4) Disconnect the connector from throttle body.

FU-02111

5) Disconnect the engine coolant hoses (A) from

the throttle body.
6) Remove the bolts (B) which secure throttle body
to intake manifold.
(A)
(B)

(B)

(A) FU-02112

B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Use new O-rings.
Tightening torque:
8 N·m (0.8 kgf-m, 5.9 ft-lb)

FU(H6DO)-13
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

3. Intake Manifold 9) Disconnect the PCV hose.

A: REMOVAL
1) Remove the collector cover.
2) Release the fuel pressure. <Ref. to FU(H6DO)-
43, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
3) Open the fuel filler lid, and remove the fuel filler
cap.
4) Disconnect the ground cable from battery.
EC-02202

10) Disconnect the brake booster hose.

IN-00203

5) Remove the air cleaner case and air intake

chamber. <Ref. to IN(H6DO)-5, REMOVAL, Air FU-03219
Cleaner Case.> <Ref. to IN(H6DO)-7, REMOVAL,
Air Intake Chamber.> 11) Disconnect the fuel hoses from the fuel pipe.
6) Disconnect the connector (A) from the throttle (1) Disconnect the connector of fuel pipe by
body. pushing the ST in the direction of arrow.
7) Disconnect the engine harness connector (B). ST 42099AE000 QUICK CONNECTOR
RELEASE
(2) Remove the clip and disconnect the evapo-
ration hose from the pipe.
(A)
CAUTION:
• Be careful not to spill fuel.
• Catch the fuel from hoses using a container
or cloth.

(B)

FU-02845

8) Disconnect the engine coolant hoses from the

throttle body.
ST

FU-02866

FU-02114

FU(H6DO)-14
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

12) Remove the EGR pipe from EGR valve. 18) Remove the bolts which hold the fuel injector
NOTE: pipe RH to the cylinder head.
Be careful not to drop the gasket.

FU-02120

FU-00547 19) Remove the bolts which hold the intake mani-
13) Remove the fuel pipe protector LH. fold to the cylinder head.
• LH side

FU-02117
FU-02121
14) Remove the engine harness from the fuel injec-
tor pipe LH. • RH side
15) Remove the bolts which hold fuel injector pipe
LH to cylinder head.

FU-02122

20) Remove the intake manifold.

FU-02118

16) Remove the fuel pipe protector RH.

FU-02119

17) Remove the engine harness from the fuel injec-

tor pipe RH.

FU(H6DO)-15
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 4) Install the fuel pipe protector RH.

1) Install the intake manifold onto cylinder heads. Tightening torque:
NOTE: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
Use new O-rings.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
• RH side

FU-02119

5) Install the bolts which hold fuel injector pipe LH

to cylinder head.
NOTE:
FU-02122 Use new O-rings.
• LH side Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-02121
FU-02118
2) Install the bolts which hold fuel injector pipe RH
to cylinder head. 6) Install the engine harness to fuel injector pipe
NOTE: LH.
Use new O-rings. 7) Install the fuel pipe protector LH.

Tightening torque: Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb) 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-02117
FU-02120

3) Install the engine harness to fuel injector pipe

RH.

FU(H6DO)-16
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

8) Install the EGR pipe to EGR valve. 12) Connect the engine coolant hoses to throttle
NOTE: body.
Use a new gasket.
Tightening torque
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-02114

13) Connect the connector (A) to throttle body.

14) Connect the engine harness connector (B).
FU-00547

9) Connect the fuel hoses to fuel pipe. (A)

(B)

FU-02845

15) Install the air cleaner case and air intake cham-
ber. <Ref. to IN(H6DO)-6, INSTALLATION, Air
FU-03218
Cleaner Case.> <Ref. to IN(H6DO)-7, INSTALLA-
10) Connect the brake booster hose. TION, Air Intake Chamber.>
16) Install the fuse of fuel pump to the main fuse
box.
17) Connect the ground cable to battery.

FU-03219

11) Connect the PCV hose.

IN-00203

18) Install the collector cover.

EC-02202

FU(H6DO)-17
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

C: DISASSEMBLY D: ASSEMBLY
1) Remove the engine harness from intake mani- NOTE:
fold. When assembling the nipple, apply liquid gasket.
2) Remove the throttle body. <Ref. to FU(H6DO)-
13, REMOVAL, Throttle Body.> Liquid gasket:
3) Remove the EGR valve. <Ref. to FU(H6DO)-27, THREE BOND 1105 (Part No. 004403010) or
REMOVAL, EGR Valve.> equivalent
4) Remove the manifold absolute pressure sensor. Tightening torque:
<Ref. to FU(H6DO)-25, REMOVAL, Manifold Ab- 17 N·m (1.7 kgf-m, 12.5 ft-lb)
solute Pressure Sensor.> 1) Tighten the bolts which install fuel pipes on in-
5) Remove the purge control solenoid valve. <Ref. take manifold.
to EC(H6DO)-8, REMOVAL, Purge Control Sole-
noid Valve.> Tightening torque:
6) Loosen the clamp which holds fuel injector pipe 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
to the fuel hose, and then disconnect the pipe from
fuel hose.

FU-02125

FU-02124

7) Remove the bolts which install fuel pipes on in-

take manifold.

FU-02126

2) Connect the fuel injector pipe to fuel hose, and

tighten the clamp screw.
Tightening torque:
FU-02125
1.25 N·m (0.1 kgf-m, 0.9 ft-lb)

FU-02126 FU-02124

3) Install the purge control solenoid valve. <Ref. to

EC(H6DO)-8, INSTALLATION, Purge Control So-
lenoid Valve.>

FU(H6DO)-18
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

4) Install the manifold absolute pressure sensor.

<Ref. to FU(H6DO)-25, INSTALLATION, Manifold
Absolute Pressure Sensor.>
5) Install the EGR valve. <Ref. to FU(H6DO)-27,
INSTALLATION, EGR Valve.>
6) Install the throttle body to the intake manifold.
<Ref. to FU(H6DO)-13, INSTALLATION, Throttle
Body.>
7) Install the engine harness to the intake manifold.
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
damaged and the connections are tightened firmly.

FU(H6DO)-19
 Engine Coolant Temperature Sensor
FUEL INJECTION (FUEL SYSTEMS)

4. Engine Coolant Temperature

Sensor
A: REMOVAL
1) Remove the collector cover.
2) Disconnect the ground cable from battery.

IN-00203

3) Drain engine coolant. <Ref. to CO(H6DO)-10,

DRAINING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
4) Disconnect the connectors from the engine cool-
ant temperature sensor.

FU-00572

5) Remove the engine coolant temperature sensor.

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)

FU-00572

FU(H6DO)-20
 Crankshaft Position Sensor
FUEL INJECTION (FUEL SYSTEMS)

5. Crankshaft Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Remove the collector cover. Tightening torque:
2) Disconnect the ground cable from battery. 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-02128
IN-00203

3) Remove the air intake chamber. <Ref. to

IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
4) Remove the service hole cover.

FU-02127

5) Remove the crankshaft position sensor.

FU-02128

6) Disconnect the connector from crankshaft posi-

tion sensor.

FU(H6DO)-21
 Camshaft Position Sensor
FUEL INJECTION (FUEL SYSTEMS)

6. Camshaft Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Remove the collector cover. Tightening torque:
2) Disconnect the ground cable from the battery. Camshaft position sensor
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
Fuel pipe protector
19 N·m (1.9 kgf-m, 14.0 ft-lb)

IN-00203

3) Remove the generator harness from the fuel

pipe protector LH.
4) Remove the fuel pipe protector LH.

FU-02117

5) Disconnect the connector from camshaft posi-

tion sensor LH.

FU-02129

6) Remove the camshaft position sensor LH.

FU-02130

7) Remove the camshaft position sensor RH in the

same procedure as LH.

FU(H6DO)-22
 Knock Sensor
FUEL INJECTION (FUEL SYSTEMS)

7. Knock Sensor B: INSTALLATION

1) Install the knock sensor to cylinder block.
A: REMOVAL
1) Remove the collector cover. Tightening torque:
2) Disconnect the ground cable from battery. 25 N·m (2.5 kgf-m, 18.4 ft-lb)
NOTE:
For the knock sensor installation angle, refer to the
figure below.
30˚ 10˚ 45˚

IN-00203

3) Remove the intake manifold. <Ref. to

FU(H6DO)-14, REMOVAL, Intake Manifold.>
4) Disconnect the knock sensor connector. (A) FU-00578

5) Remove the knock sensor from the cylinder (A) Front side of vehicle
block.
2) Connect the knock sensor connector.
3) Install the intake manifold. <Ref. to FU(H6DO)-
16, INSTALLATION, Intake Manifold.>
4) Connect the ground cable to battery.

FU-00577

IN-00203

5) Install the collector cover.

FU(H6DO)-23
 Throttle Position Sensor
FUEL INJECTION (FUEL SYSTEMS)

8. Throttle Position Sensor

A: SPECIFICATION
Throttle body is a non-disassembled part, so do not
remove the throttle position sensor from throttle
body.
Refer to “Throttle Body” for removal and installation
procedure. <Ref. to FU(H6DO)-13, REMOVAL,
Throttle Body.> <Ref. to FU(H6DO)-13, INSTAL-
LATION, Throttle Body.>

FU(H6DO)-24
 Manifold Absolute Pressure Sensor
FUEL INJECTION (FUEL SYSTEMS)

9. Manifold Absolute Pressure

Sensor
A: REMOVAL
1) Remove the collector cover.
2) Disconnect the ground cable from the battery.

IN-00203

3) Disconnect the connector from the manifold ab-

solute pressure sensor (A), and remove the filter
assembly (B) from the intake manifold.

(A) (B)

FU-02131

4) Remove the manifold absolute pressure sensor

from intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU(H6DO)-25
 Mass Air Flow and Intake Air Temperature Sensor
FUEL INJECTION (FUEL SYSTEMS)

[Link] Air Flow and Intake Air

Temperature Sensor
A: REMOVAL
1) Disconnect the ground cable from the battery.

IN-00203

2) Disconnect the connectors from the mass air

flow and intake air temperature sensor.

IN-02009

3) Remove the mass air flow and intake air temper-

ature sensor.

FU-03236

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
1 N·m (0.1 kgf-m, 0.7 ft-lb)

FU(H6DO)-26
 EGR Valve
FUEL INJECTION (FUEL SYSTEMS)

[Link] Valve
A: REMOVAL
1) Remove the collector cover.
2) Disconnect the ground cable from battery.

IN-00203

3) Remove the air intake chamber. <Ref. to

IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
4) Remove the starter. <Ref. to SC(H4SO)-6, RE-
MOVAL, Starter.>
5) Remove the EGR pipe from EGR valve and cyl-
inder head.
6) Remove the EGR valve from intake manifold.

FU-02133

7) Disconnect the connector from the EGR valve.

B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Use a new gasket.
Tightening torque:
EGR valve
19 N·m (1.9 kgf-m, 14.0 ft-lb)
EGR pipe
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-02133

FU(H6DO)-27
 Fuel Injector
FUEL INJECTION (FUEL SYSTEMS)

[Link] Injector 9) Remove the bolt which holds fuel injector pipe
onto cylinder head.
A: REMOVAL
1. RH SIDE
1) Remove the collector cover.
2) Release the fuel pressure. <Ref. to FU(H6DO)-
43, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
3) Open the fuel filler lid, and remove the fuel filler
cap.
4) Disconnect the ground cable from battery.
FU-02120

10) Remove the fuel injector while lifting up the fuel

injector pipe.
2. LH SIDE
1) Remove the collector cover.
2) Release the fuel pressure. <Ref. to FU(H6DO)-
43, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
3) Open the fuel filler lid, and remove the fuel filler
IN-00203 cap.
5) Remove the air cleaner case. <Ref. to 4) Remove the battery. <Ref. to SC(H4SO)-20,
IN(H6DO)-5, REMOVAL, Air Cleaner Case.> REMOVAL, Battery.>
6) Remove the fuel pipe protector RH. 5) Remove the generator harness from the fuel
pipe protector LH.
6) Remove the fuel pipe protector LH.

FU-02119

7) Disconnect the connector from fuel injector.

FU-02117

7) Disconnect the connector from fuel injector.

FU-02134

8) Remove the engine harness from the fuel injec-

FU-02135
tor pipe RH.
8) Remove the engine harness from the fuel injec-
tor pipe LH.

FU(H6DO)-28
 Fuel Injector
FUEL INJECTION (FUEL SYSTEMS)

9) Remove the bolt which holds fuel injector pipe 2. LH SIDE

onto cylinder head. Install in the reverse order of removal.
NOTE:
Use new O-rings.
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-02118

10) Remove the fuel injector while lifting up the fuel

injector pipe.
B: INSTALLATION
1. RH SIDE FU-02118

Install in the reverse order of removal. Tightening torque:

NOTE: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
Use new O-rings.
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-02117

FU-02120

Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-02119

FU(H6DO)-29
 Variable Valve Lift Diagnosis Oil Pressure Switch
FUEL INJECTION (FUEL SYSTEMS)

[Link] Valve Lift Diagnosis B: INSTALLATION

Oil Pressure Switch Install in the reverse order of removal.
NOTE:
A: REMOVAL Apply liquid gasket to the variable valve lift diagno-
1) Remove the collector cover. sis oil pressure switch threads.
2) Disconnect the ground cable from battery.
Liquid gasket:
THREE BOND 1324 (Part No. 004403042) or
equivalent
Tightening torque:
17 N·m (1.7 kgf-m, 12.5 ft-lb)

IN-00203

3) Remove the air intake chamber. <Ref. to

IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
4) Disconnect the connector from the variable
valve lift diagnosis oil pressure switch.
5) Remove the variable valve lift diagnosis oil pres-
sure switch.
• LH side

FU-02136

• RH side

FU-02137

FU(H6DO)-30
 Oil Temperature Sensor
FUEL INJECTION (FUEL SYSTEMS)

[Link] Temperature Sensor

A: REMOVAL
1) Remove the collector cover.
2) Disconnect the ground cable from battery.

IN-00203

3) Remove the air intake chamber. <Ref. to

IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
4) Disconnect the connector from the oil tempera-
ture sensor.

FU-02138

5) Remove the oil temperature sensor.

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)

FU(H6DO)-31
 Front Oxygen (A/F) Sensor
FUEL INJECTION (FUEL SYSTEMS)

[Link] Oxygen (A/F) Sensor 6) Remove the front oxygen (A/F) sensor.
CAUTION:
A: REMOVAL When removing the front oxygen (A/F) sensor,
1) Set the vehicle on a lift. wait until exhaust pipe cools, otherwise it will
2) Disconnect the ground cable from the battery. damage the exhaust pipe.
• LH side

IN-00203

3) Lift up the vehicle. FU-02141

4) Disconnect the connector of front oxygen (A/F) • RH side

sensor.
• LH side

FU-02142

FU-02139

• RH side

FU-02140

5) Apply spray-type lubricant to the threaded por-

tion of front oxygen (A/F) sensor, and leave it for
one minute or more.

FU(H6DO)-32
 Front Oxygen (A/F) Sensor
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 3) Connect the connector of front oxygen (A/F)

sensor.
CAUTION: • LH side
If lubricant is spilt onto 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, ap-
ply anti-seize compound only to the threaded por-
tion of front oxygen (A/F) sensor to make the next
removal easier.
CAUTION:
Never apply anti-seize compound to the protec-
tor of front oxygen (A/F) sensor.
FU-02139
Anti-seize compound: • RH side
NEVER-SEEZ NSN, JET LUBE SS-30 or
equivalent
2) Install the front oxygen (A/F) sensor.
Tightening torque:
21 N·m (2.1 kgf-m, 15.5 ft-lb)
• LH side

FU-02140

4) Lower the vehicle.

5) Connect the ground cable to battery.

FU-02141

• RH side

IN-00203

FU-02142

FU(H6DO)-33
 Rear Oxygen Sensor
FUEL INJECTION (FUEL SYSTEMS)

[Link] Oxygen Sensor 7) Remove the rear oxygen sensor.

CAUTION:
A: REMOVAL When removing the rear oxygen sensor, wait
1) Set the vehicle on a lift. until exhaust pipe cools, otherwise it will dam-
2) Disconnect the ground cable from the battery. age the exhaust pipe.
• LH side

IN-00203

3) Lift up the vehicle. FU-02145

4) Disconnect the connector from rear oxygen sen- • RH side

sor.
• LH side

FU-02146

FU-02143

• RH side

FU-02144

5) Remove the clip holding the harness.

6) Apply spray-type lubricant to the threaded por-
tion of rear oxygen sensor, and leave it for one
minute or more.

FU(H6DO)-34
 Rear Oxygen Sensor
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 4) Connect the connector to rear oxygen sensor.

• LH side
CAUTION:
If lubricant is spilt onto 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 eas-
ier.
CAUTION:
Never apply anti-seize compound to the protec-
FU-02143
tor of rear oxygen sensor.
• RH side
Anti-seize compound:
NEVER-SEEZ NSN, JET LUBE SS-30 or
equivalent
2) Install the rear oxygen sensor.
Tightening torque:
21 N·m (2.1 kgf-m, 15.5 ft-lb)
• LH side

FU-02144

5) Lower the vehicle.

6) Connect the ground cable to battery.

FU-02145

• RH side

IN-00203

FU-02146

3) Hold the harness with clip.

FU(H6DO)-35
 SI-DRIVE (SUBARU Intelligent Drive) Selector
FUEL INJECTION (FUEL SYSTEMS)

[Link]-DRIVE (SUBARU Intelligent B: INSTALLATION

Drive) Selector Install in the reverse order of removal.

A: REMOVAL C: INSPECTION
1) Disconnect the ground cable from battery. Measure the resistance between SI-DRIVE selec-
tor terminals.

5 4 3 2 1

IN-00203
FU-03123
2) Remove the console box. <Ref. to EI-52, RE-
MOVAL, Glove Box.> Switch position Terminal No. Standard value
3) Disconnect the SI-DRIVE selector connector. Sport
(when turning the SI- Less than 10
DRIVE selector to the left)
Intelligent
(when pushing the SI- 2 and 3 0.8 — 1.2 k
DRIVE selector)
Sport Sharp
(when turning the SI- 2.14 — 3.2 k
DRIVE selector to the right)

FU-04006

4) Remove the screws which secure the SI-DRIVE

selector to the console box.

FU-04007

5) Disconnect the connector from SI-DRIVE selec-

tor cover, and remove the SI-DRIVE selector.

FU-04008

FU(H6DO)-36
 SI-DRIVE (SUBARU Intelligent Drive) S# Switch
FUEL INJECTION (FUEL SYSTEMS)

[Link]-DRIVE (SUBARU Intelligent C: INSPECTION

Drive) S# Switch Measure the resistance between SI-DRIVE S#
switch terminals.
A: REMOVAL
1) Disconnect the ground cable from battery.
4 3 2 1

FU-03121

Switch position Terminal No. Standard value

IN-00203
ON (When the SI-DRIVE
2) Remove the airbag module. <Ref. to AB-14, RE- Less than 10
S# switch is pressed) 3 and 4
MOVAL, Driver’s Airbag Module.> OFF 1M or more
WARNING:
Always refer to “Airbag System” before per-
forming service on the airbag modules. <Ref. to
AB-4, CAUTION, General Description.>
3) Remove the screws which secure the SI-DRIVE
S# switch to the steering wheel, and remove the SI-
DRIVE S# switch.

FU-03122

4) Disconnect the connectors from the SI-DRIVE

S# switch.
B: INSTALLATION
Install in the reverse order of removal.

FU(H6DO)-37
 Engine Control Module (ECM)
FUEL INJECTION (FUEL SYSTEMS)

[Link] Control Module (ECM) B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground cable from battery. CAUTION:
When the ECM of model with immobilizer has
been replaced, be sure to perform the registra-
tion of immobilizer system. (Refer to the “PC
application help for Subaru Select Monitor”.)
NOTE:
When replacing the ECM, be careful not to use the
wrong spec. ECM to avoid any damage on the fuel
injection system.
Tightening torque:
IN-00203 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
2) Remove the lower inner trim of passenger’s
side. <Ref. to EI-61, REMOVAL, Lower Inner
Trim.>
3) Detach the floor mat of passenger’s seat.
4) Remove the protect cover.

FU-02090

5) Remove the nuts and bolts which hold the ECM

to the bracket.
6) Remove the clip (A) from bracket.

(A)

FU-02488

7) Disconnect the ECM connectors, and take out

the ECM.

FU(H6DO)-38
 Main Relay
FUEL INJECTION (FUEL SYSTEMS)

[Link] Relay
A: REMOVAL
1) Disconnect the ground cable from battery.

IN-00203

2) Remove the glove box. <Ref. to EI-52, REMOV-

AL, Glove Box.>
3) Remove the harness cover (A).

(A)

FU-02092

4) Disconnect the connectors from main relay.

FU-02406

B: INSTALLATION
Install in the reverse order of removal.

FU(H6DO)-39
 Fuel Pump Relay
FUEL INJECTION (FUEL SYSTEMS)

[Link] Pump Relay

A: REMOVAL
1) Disconnect the ground cable from battery.

IN-00203

2) Remove the glove box. <Ref. to EI-52, REMOV-

AL, Glove Box.>
3) Remove the harness cover (A).

(A)

FU-02092

4) Disconnect the connector from fuel pump relay.

FU-02407

B: INSTALLATION
Install in the reverse order of removal.

FU(H6DO)-40
 Electronic Throttle Control Relay
FUEL INJECTION (FUEL SYSTEMS)

[Link] Throttle Control

Relay
A: REMOVAL
1) Disconnect the ground cable from battery.

IN-00203

2) Remove the glove box. <Ref. to EI-52, REMOV-

AL, Glove Box.>
3) Remove the harness cover (A).

(A)

FU-02092

4) Disconnect the connector from electronic throttle

control relay.

FU-02408

B: INSTALLATION
Install in the reverse order of removal.

FU(H6DO)-41
 Fuel Pump Control Unit
FUEL INJECTION (FUEL SYSTEMS)

[Link] Pump Control Unit 5) Disconnect the connector from fuel pump control
unit.
A: REMOVAL B: INSTALLATION
1) Disconnect the ground cable from battery.
Install in the reverse order of removal.
Tightening torque:
5 N·m (0.5 kgf-m, 3.7 ft-lb)

IN-00203

2) Remove the rear quarter trim of the left side.

(Wagon model) <Ref. to EI-63, REMOVAL, Rear
Quarter Trim.>
3) Peel the trunk side trim of the left side. (Sedan
model)
4) Remove the fuel pump control unit.
• Wagon model

FU-03220

• Sedan model

FU-03231

FU(H6DO)-42
 Fuel
FUEL INJECTION (FUEL SYSTEMS)

[Link] 2. DRAINING FUEL

(WITH SUBARU SELECT MONITOR)
A: PROCEDURE WARNING:
1. RELEASING OF FUEL PRESSURE Place “NO OPEN FLAMES” signs near the
working area.
WARNING:
Place “NO OPEN FLAMES” signs near the CAUTION:
working area. Be careful not to spill fuel.
CAUTION: NOTE:
Be careful not to spill fuel. • If the fuel pump cannot be actuated, refer to
1) Remove the fuse of fuel pump from main fuse DRAINING FUEL (THROUGH THE FUEL FILLER
box. HOSE). <Ref. to FU(H6DO)-44, DRAINING FUEL
(THROUGH THE FUEL FILLER HOSE), PROCE-
DURE, Fuel.>
• Be careful not to let the battery run-out.
1) Release the fuel pressure. <Ref. to FU(H6DO)-
43, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
2) Attach ST to the fuel delivery pipe and push ST
in the direction of arrow mark to disconnect the fuel
delivery hose.
ST 42099AE000 QUICK CONNECTOR
FU-01122
RELEASE
2) Start the engine and run it until it stalls. CAUTION:
3) After the engine stalls, crank it for five more sec- • Be careful not to spill fuel.
onds. • Catch the fuel from hoses using a container
4) Turn the ignition switch to OFF. or cloth.

ST

FU-02866

3) Connect ST to the fuel delivery hose.

ST 18471AA000 FUEL PIPE ADAPTER
4) Connect the gasoline proof hose to ST and put
the end of the hose in the container.
5) Drive the fuel pump and drain the fuel using Sub-
aru Select Monitor. <Ref. to EN(H6DO)(diag)-54,
FUEL PUMP CONTROL (ON/OFF OPERATION),
OPERATION, System Operation Check Mode.>
CAUTION:
Be careful not to spill fuel.

FU(H6DO)-43
 Fuel
FUEL INJECTION (FUEL SYSTEMS)

3. DRAINING FUEL
(THROUGH THE FUEL FILLER HOSE)
WARNING:
Place “NO OPEN FLAMES” signs near the
working area.
CAUTION:
• Be careful not to spill fuel.
• Fuel may remain in the fuel filler pipe. Drain-
ing the fuel from the fuel filler pipe through the
fill opening using the gasoline proof pump and
the gasoline proof hose (ø10 or less) before the
operation.
1) Set the vehicle on a lift.
2) Lift up the vehicle.
3) Remove the rear exhaust pipe and muffler.
<Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.>
4) Open the fuel filler lid, and remove the fuel filler
cap.
5) Drain the fuel from the fuel filler pipe through the
filler opening using the gasoline proof pump and
the gasoline proof hose (ø10 or less).
6) Disconnect the fuel filler hose (A) from the fuel
filler pipe.
CAUTION:
• Be careful not to spill fuel.
• Catch the fuel from hoses using a container
or cloth.

(B)

(A)

FU-02394

(A) Fuel filler hose

(B) Evaporation hose

7) Set the container under the vehicle and insert

the gasoline proof hose (ø10 or less) into the fuel
filler hose to drain the fuel.
CAUTION:
Be careful not to spill fuel.

FU(H6DO)-44
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

[Link] Tank 8) Remove the connector (A) and clip (B).

A: REMOVAL (B)
(A)
WARNING:
Place “NO OPEN FLAMES” signs near the
working area.
CAUTION:
Be careful not to spill fuel.
1) Set the vehicle on a lift.
2) Release the fuel pressure. <Ref. to FU(H6DO)-
FU-03222
43, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.> 9) Remove the service hole cover of fuel sub level
3) Drain fuel. <Ref. to FU(H6DO)-43, DRAINING sensor.
FUEL (WITH SUBARU SELECT MONITOR), (1) Remove the bolt (A).
PROCEDURE, Fuel.> (2) Push the grommet (B) down and remove the
4) Disconnect the ground cable from battery. service hole cover.

(A)

(A)

(B)
IN-00203 FU-03223

5) Remove the rear seat. 10) Disconnect connector (A) from fuel sub level
6) Remove the service hole cover of fuel pump. sensor.
11) Disconnect the quick connector on the fuel de-
livery hose (B). <Ref. to FU(H6DO)-65, REMOVAL,
Fuel Delivery and Evaporation Lines.>

(A)

FU-02387

7) Disconnect the connector from fuel pump.

(B)
FU-02853

12) Remove the trunk room trim. (Sedan model)

<Ref. to EI-70, REMOVAL, Trunk Room Trim.>
13) Remove the rear quarter trim. (Wagon model)
<Ref. to EI-63, WAGON MODEL, REMOVAL, Rear
Quarter Trim.>

FU-03221

FU(H6DO)-45
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

14) Remove the pipe protector. 20) Remove the parking brake cable from parking
brake assembly. <Ref. to PB-6, REMOVAL, Park-
ing Brake Assembly (Rear Disc Brake).>
21) Lift up the vehicle.
22) Remove the rear exhaust pipe. <Ref. to
EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.>
23) Remove the propeller shaft. <Ref. to DS-10,
REMOVAL, Propeller Shaft.>
24) Remove the heat shield cover and fuel tank
protector.
25) Disconnect the connector from the rear ABS
FU-02390
wheel speed sensor.
15) Remove the grommet and disconnect the quick
connector of the evaporation pipe. <Ref. to
FU(H6DO)-65, REMOVAL, Fuel Delivery and
Evaporation Lines.>

FU-02894

26) Remove the bolts securing the parking brake

cable clamp.
FU-02391

16) Remove the rear wheels.

17) Lift up the vehicle.
18) Remove the bolts which secure the rear brake
hose mounting bracket.

FU-02895

FU-01128

19) Remove the rear disc brake assembly and tie it

to the body side of the vehicle.

FU-02896

FU-00462

FU(H6DO)-46
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

27) Remove the rear suspension assembly. 29) Disconnect the evaporation hose.
CAUTION:
A helper is required to perform this work.
(1) Support the rear suspension assembly with
the transmission jack.
(2) Remove the bolts which hold the rear shock
absorber to the rear suspension arm.

FU-02393

30) Disconnect the fuel filler hose (A) and evapora-

tion hose (B).

FU-01132

(3) Remove the bolts which secure the rear

suspension assembly to the body. (B)

(A)

FU-02394

31) Support the fuel tank with a transmission jack,

remove the bolts from the fuel tank band, and re-
move the fuel tank from the vehicle.
WARNING:
• A helper is required to perform this work.
FU-01133
• Fuel may remain in the fuel tank. This will
cause the left and right sides to be unbalanced.
Be careful not to drop the fuel tank when re-
moving.

FU-02891

(4) Remove the rear suspension assembly.

28) Disconnect the connector.
FU-03293

FU-02392

FU(H6DO)-47
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 3) Connect the evaporation hose.

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.
WARNING:
A helper is required to perform this work.

FU-02393

4) Tighten the fuel tank band bolts.

Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
5) Connect the connector.
FU-03293

2) Securely insert the fuel filler hose (A) and evap-

oration hose (B) to the specified position, then tight-
en the clip or clamp.

(B) FU-02392

(A)

FU-02394

(2) (3)
(1)

L/2

L
FU-00104

(1) Hose
(2) Clip or clamp
(3) Pipe

FU(H6DO)-48
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

6) Install the rear suspension assembly. 7) Tighten the bolts holding the parking brake cable
CAUTION: clamp.
A helper is required to perform this work. Tightening torque:
(1) Support the rear suspension assembly with 18 N·m (1.8 kgf-m, 13.3 ft-lb)
a transmission jack.
(2) Support the rear suspension assembly, and
tighten the bolts which secure the rear suspen-
sion assembly to the body.
Tightening torque:
T1: 125 N·m (12.7 kgf-m, 92.2 ft-lb)
T2: 175 N·m (17.8 kgf-m, 129.1 ft-lb)

T1 T1
FU-02895

T1
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)

T1

FU-01150

FU-02896

8) Connect the connector to the rear ABS wheel

T2 speed sensor.
T2

FU-02892

(3) Tighten the bolts which hold the rear shock

absorber to the rear suspension arm. <Ref. to
RS-10, INSTALLATION, Rear Arm.>
Tightening torque:
62 N·m (6.3 kgf-m, 45.7 ft-lb)

FU-02894

9) Install the heat shield cover.

Tightening torque:
17.5 N·m (1.8 kgf-m, 12.9 ft-lb)
10) Install the fuel tank protector.
Tightening torque:
Nut: 9 N·m (0.9 kgf-m, 6.6 ft-lb)
FU-01132 Bolt: 17.5 N·m (1.8 kgf-m, 12.9 ft-lb)
11) Install the propeller shaft. <Ref. to DS-11, IN-
STALLATION, Propeller Shaft.>
12) Install the rear exhaust pipe. <Ref. to
EX(H6DO)-8, INSTALLATION, Rear Exhaust
Pipe.>
13) Lower the vehicle.

FU(H6DO)-49
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

14) Connect the parking brake cable to the parking 20) Install the trunk room trim. (Sedan model)
brake assembly. <Ref. to PB-7, INSTALLATION, <Ref. to EI-71, INSTALLATION, Trunk Room
Parking Brake Assembly (Rear Disc Brake).> Trim.>
15) Install the rear disc brake assembly. 21) Install the rear quarter trim. (Wagon model)
<Ref. to EI-64, INSTALLATION, Rear Quarter
Tightening torque:
Trim.>
66 N·m (6.7 kgf-m, 48.7 ft-lb)
22) Connect connector (A) to the fuel sub level sen-
16) Tighten the bolts which secure the rear brake sor.
hose mounting bracket.
23) Connect the quick connector of the fuel delivery
Tightening torque: hose (B). <Ref. to FU(H6DO)-66, INSTALLATION,
33 N·m (3.4 kgf-m, 24.3 ft-lb) Fuel Delivery and Evaporation Lines.>

(A)

(B)
FU-01128 FU-02853

17) Install the rear wheels. 24) Install the service hole cover of fuel sub level
sensor.
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
18) Connect the quick connector of the evaporation (A)
pipe. <Ref. to FU(H6DO)-66, INSTALLATION, Fuel
Delivery and Evaporation Lines.>

(A)

(B)
FU-03223

(A) Bolt
(B) Grommet

FU-02391 25) Connect connector (A) and install clip (B).

19) Install the pipe protector. (B)
Tightening torque: (A)
T1: 1 N·m (0.1 kgf-m, 0.7 ft-lb)
T2: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

T2

FU-03222

T1

FU-02868

FU(H6DO)-50
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

26) Connect the connector to the fuel pump.

FU-03221

27) Install the service hole cover of fuel pump.

FU-02387

28) Install the rear seat.

29) Install the fuse of fuel pump to the main fuse
box.
30) Connect the ground cable to battery.

IN-00203

31) Inspect the wheel alignment and adjust if nec-

essary.
C: INSPECTION
1) Check that the fuel tank does not have holes,
cracks or is damaged in any way.
2) Make sure that the fuel pipe and fuel hose are
not cracked and that the connections are tight.

FU(H6DO)-51
 Fuel Filler Pipe
FUEL INJECTION (FUEL SYSTEMS)

[Link] Filler Pipe 11) Remove the bolts which hold fuel filler pipe
bracket on the body.
A: REMOVAL
WARNING:
Place “NO OPEN FLAMES” signs near the
working area.
CAUTION:
Be careful not to spill fuel.
1) Set the vehicle on a lift.
2) Release the fuel pressure. <Ref. to FU(H6DO)-
43, RELEASING OF FUEL PRESSURE, PROCE-
FU-02395
DURE, Fuel.>
3) Drain fuel. <Ref. to FU(H6DO)-43, DRAINING 12) Disconnect the fuel filler hose (A) and evapora-
FUEL (WITH SUBARU SELECT MONITOR), tion hose (B).
PROCEDURE, Fuel.>
4) Disconnect the ground cable from battery.

(B)

(A)

FU-02396

IN-00203
(B)
5) Open the fuel filler lid, and remove the filler cap.
6) Remove the screws which secure gasket.

FU-02397

13) Remove the fuel filler pipe to the underside of

the vehicle.
FU-00095

7) Remove the rear wheel RH.

8) Lift up the vehicle.
9) Remove the mud guard. <Ref. to EI-29, RE-
MOVAL, Mud Guard.>
10) Remove the rear sub frame. <Ref. to RS-21,
REMOVAL, Rear Sub Frame.>

FU(H6DO)-52
 Fuel Filler Pipe
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION
(2) (3)
1) Open the fuel filler lid. (1)

2) Set the fuel saucer (A) with rubber gasket (C),

and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.
L/2
NOTE:
If the edges of rubber gasket are folded toward in- L
FU-00104
side, straighten it with a flat tip screwdriver.
(A) (1) Hose
(2) Clip or clamp
(3) Pipe

5) Tighten the bolts which hold fuel filler pipe brack-

(B) et on the body.
Tightening torque:
(C)
7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
FU-00103

4) Securely insert the fuel filler hose (A) and evap-

oration hose (B) into the specified position, then
tighten the clamp or clip as shown in the figure.
Tightening torque:
2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

FU-02395

6) Install the rear sub frame. <Ref. to RS-21, IN-

STALLATION, Rear Sub Frame.>
(B) 7) Install the mud guard. <Ref. to EI-29, INSTAL-
LATION, Mud Guard.>
(A)
8) Lower the vehicle.
9) Install the rear wheel RH.
FU-02396
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
(B)
10) Connect the ground cable to battery.

FU-02397

IN-00203

11) Inspect the wheel alignment and adjust if nec-

essary.

FU(H6DO)-53
 Fuel Filler Pipe
FUEL INJECTION (FUEL SYSTEMS)

C: INSPECTION E: ASSEMBLY
1) Check that the fuel tank does not have holes, 1) Install the shut valve to the fuel filler pipe. <Ref.
cracks or is damaged in any way. to EC(H4SO)-15, INSTALLATION, Shut Valve.>
2) Make sure that the fuel hose is not cracked and 2) Tighten the nuts which secure the evaporation
that the connections are tight. pipe assembly to the fuel filler pipe.
D: DISASSEMBLY Tightening torque:
1) Move the clip and disconnect the evaporation 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
hose from the shut valve.

FU-02399

FU-02398

2) Remove the nut which holds the evaporation

pipe assembly to the fuel filler pipe.

FU-02400

3) Connect the evaporation hose to the shut valve.

FU-02399

FU-02398

FU-02400

3) Remove the shut valve from the fuel filler pipe.

<Ref. to EC(H4SO)-15, REMOVAL, Shut Valve.>

FU(H6DO)-54
 Fuel Pump
FUEL INJECTION (FUEL SYSTEMS)

[Link] Pump 6) Disconnect the connector from fuel pump.

A: REMOVAL
WARNING:
Place “NO OPEN FLAMES” signs near the
working area.
CAUTION:
• 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
FU-03221
fuel before starting work to avoid the fuel to
spill. 7) Disconnect the quick connector on the fuel deliv-
NOTE: ery hose and jet pump hose. <Ref. to FU(H6DO)-
Fuel pump assembly consists of fuel pump, fuel fil- 65, REMOVAL, Fuel Delivery and Evaporation
ter and fuel level sensor. Lines.>
1) Release the fuel pressure. <Ref. to FU(H6DO)-
43, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
(B)
2) Drain fuel. <Ref. to FU(H6DO)-43, DRAINING
FUEL (WITH SUBARU SELECT MONITOR),
PROCEDURE, Fuel.>
3) Disconnect the ground cable from battery.

(A)
FU-02670

(A) Fuel delivery hose

(B) Jet pump hose

8) Remove the nuts which install fuel pump assem-

bly onto fuel tank.
9) Remove the fuel pump assembly from the fuel
IN-00203 tank.
4) Remove the rear seat.
5) Remove the service hole cover.

FU-02387

FU(H6DO)-55
 Fuel Pump
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION
Install in the reverse order of removal while being
careful of the following.
• Make sure the sealing portion is free from fuel or
foreign matter before installation.
• When assembling, point the protrusion of the
gasket (A) towards the front of the vehicle.
• Insert the protrusion (B) of the gasket into the up-
per plate. (3 places)
• Align the protrusion (C) of the fuel pump assem-
bly to the cut out in the upper plate.
• Tighten the nuts to the specified torque in the or-
der as shown in the figure.
NOTE:
Use new gasket and retainer.
Tightening torque:
4.4 N·m (0.4 kgf-m, 3.2 ft-lb)
(C)
1
4 8
(B) (B)

6 5

7 3

2 (A)
(B) FU-02835

C: INSPECTION
Connect the lead harness to the connector terminal
of fuel pump, and apply the battery power supply to
check whether the pump operates.
CAUTION:
• Wipe off fuel completely.
• Keep the battery as far apart from fuel pump
as possible.
• Be sure to perform the ON/OFF operation on
the battery side.
• Do not run the fuel pump for a long time un-
der non-load condition.

2 1
4 3
6 5

FU-01330

FU(H6DO)-56
 Fuel Level Sensor
FUEL INJECTION (FUEL SYSTEMS)

[Link] Level Sensor

A: REMOVAL
WARNING:
Place “NO OPEN FLAMES” signs near the
working area.
CAUTION:
• 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.
NOTE:
The fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(H6DO)-55, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.
3) Remove the fuel temperature sensor.
4) Remove the fuel level sensor.

(A)
(C)

(B)

FU-04001

(A) Connector
(B) Fuel temperature sensor
(C) Fuel level sensor

B: INSTALLATION
Install in the reverse order of removal.

FU(H6DO)-57
 Fuel Sub Level Sensor
FUEL INJECTION (FUEL SYSTEMS)

[Link] Sub Level Sensor 6) Disconnect the connector from the fuel sub level
sensor.
A: REMOVAL
WARNING:
Place “NO OPEN FLAMES” signs near the
working area.
CAUTION:
• 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
FU-03010
spill.
1) Release the fuel pressure. <Ref. to FU(H6DO)- 7) Disconnect the quick connector on the fuel deliv-
43, RELEASING OF FUEL PRESSURE, PROCE- ery hose and jet pump hose. <Ref. to FU(H6DO)-
DURE, Fuel.> 65, REMOVAL, Fuel Delivery and Evaporation
2) Drain fuel. <Ref. to FU(H6DO)-43, DRAINING Lines.>
FUEL (WITH SUBARU SELECT MONITOR), 8) Remove the nuts and bolts which install fuel sub
PROCEDURE, Fuel.> level sensor on fuel tank.
3) Disconnect the ground cable from battery.

(A)

(B)
FU-02673
IN-00203
(A) Jet pump hose
4) Remove the rear seat. (B) Fuel delivery hose
5) Remove the service hole cover.
(1) Remove bolt (A). 9) Remove the fuel sub level sensor.
(2) Push the grommet (B) down and remove the
service hole cover.

(A)

(A)

(B)
FU-03223

FU(H6DO)-58
 Fuel Sub Level Sensor
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION
Install in the reverse order of removal while being
careful of the following.
• Make sure the sealing portion is free from fuel or
foreign matter before installation.
• Align protrusion (A) of the gasket to the position
shown in the following figure.
• Align the protrusion (B) of fuel sub level sensor
with the cutout on the upper plate of fuel sub level
sensor.
• Tighten the nuts and bolts to the specified torque
in the order as shown in the figure.
NOTE:
Use a new gasket and retainer.
Tightening torque:
4.4 N·m (0.4 kgf-m, 3.2 ft-lb)
3
1

2 (B)
4
(A) FU-02836

FU-02674

FU(H6DO)-59
 Fuel Filter
FUEL INJECTION (FUEL SYSTEMS)

[Link] Filter 5) Disconnect the fuel piping connector from the

fuel filter assembly in two locations.
A: REMOVAL
WARNING:
Place “NO OPEN FLAMES” signs near the
working area.
CAUTION:
• 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
FU-03851
spill.
• Be careful not to drop or apply any impact to 6) Push to compress the fuel filter assembly in the
the fuel pump during work. This may deterio- direction of the arrow, remove clip (A), and sepa-
rate its performance. rate the sub tank bracket assembly and the fuel fil-
NOTE: ter assembly.
The fuel filter is built in fuel pump assembly. CAUTION:
1) Remove the fuel pump assembly. <Ref. to When separating the sub tank bracket assem-
FU(H6DO)-55, REMOVAL, Fuel Pump.> bly and the fuel filter assembly, be careful not
2) Remove the fuel level sensor and fuel tempera- to damage the ground wire.
ture sensor. <Ref. to FU(H6DO)-57, REMOVAL,
(A)
Fuel Level Sensor.>
3) Disconnect the pump assembly connector from
the sub tank bracket assembly.

FU-03852

7) Disconnect the connector from the pump assem-

bly.
FU-03983

4) Cut off the tab holders connecting the sub tank

bracket assembly and the sub tank in four loca-
tions, and separate the two.
CAUTION:
Be careful not to damage the sub tank.
NOTE:
If the O-ring is remaining on the subtank, remove.
FU-03986

FU-03984

FU(H6DO)-60
 Fuel Filter
FUEL INJECTION (FUEL SYSTEMS)

8) Lift the two tab holders connecting the pump as- B: INSTALLATION
sembly to the fuel filter using a flat tip screwdriver
1) Assemble o-ring (A) and spacer (B) to the fuel
[with a shaft diameter of approx. 3 mm (0.12 in)],
pump, and attach the pump assembly to the fuel fil-
etc., and separate the fuel filter and pump assem-
ter.
bly.
NOTE:
CAUTION:
• Use new O-rings [8 mm (0.31 in) inner diameter].
• To prevent damaging the tabs of the pump
assembly, wrap the tip of flat tip screwdriver • Use a new spacer.
(A), etc. with tape (B). • Apply gasoline to the o-ring.
• Insert the pump assembly until a “pop” is heard.

(B)
(A)

(B)
FU-03929

• Be careful not to drop or apply any impact to (A)

the pump assembly.
NOTE:
If the spacer and O-ring is remaining on the pump
assembly, remove these.

FU-03859

2) Connect the connector to the pump assembly.

FU-03927

FU-03986

FU(H6DO)-61
 Fuel Filter
FUEL INJECTION (FUEL SYSTEMS)

3) Attach spring (A) to the metal rod of the sub tank 5) Connect the fuel piping connector to the fuel fil-
bracket assembly, and assemble the fuel filter as- ter assembly.
sembly. NOTE:
NOTE: • Use new O-rings.
Use a new spring. • Apply gasoline to the o-ring.
• The O-rings of the black and white connectors
are identified by a difference in diameter. Be careful
not to confuse the two during assembly.
O-ring inner diameter:
Black connector O-ring [Approx. 7 mm (0.28 in)]
White connector O-ring [Approx. 8 mm (0.31 in)]

(A)
(A)
FU-03851

6) Attach the O-ring (A) to the fuel filter assembly,

and attach the subtank to the sub tank bracket as-
sembly.
FU-03985 NOTE:
4) Push the fuel filter assembly in the direction of • Use new O-rings [8 mm (0.31 in) inner diameter].
the arrow to compress, and attach clip (A). • Apply gasoline to the o-ring.
• Insert the pump assembly until a “pop” is heard.
NOTE:
Use a new clip.

(A)

FU-03861

(A)

FU-03987

FU(H6DO)-62
 Fuel Filter
FUEL INJECTION (FUEL SYSTEMS)

7) Replace the cushion on the rear face of the sub

tank with a new cushion.

FU-03863

8) Connect the pump assembly connector to the

sub tank bracket assembly.

FU-03983

9) Install the fuel level sensor and fuel temperature

sensor. <Ref. to FU(H6DO)-57, INSTALLATION,
Fuel Level Sensor.>
10) Install the fuel pump assembly. <Ref. to
FU(H6DO)-56, INSTALLATION, Fuel Pump.>

FU(H6DO)-63
 Fuel Damper
FUEL INJECTION (FUEL SYSTEMS)

[Link] Damper
A: REMOVAL
WARNING:
Place “NO OPEN FLAMES” signs near the
working area.
CAUTION:
• Be careful not to spill fuel.
• Catch the fuel from hoses using a container
or cloth.
1) Release the fuel pressure. <Ref. to FU(H6DO)-
43, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
2) Remove the fuel damper from the fuel delivery
line.

FU-03008

B: INSTALLATION
CAUTION:
If fuel hoses or clamps are damaged, replace
them with new parts.
Install in the reverse order of removal.
Tightening torque:
1.25 N·m (0.1 kgf-m, 0.9 ft-lb)

FU(H6DO)-64
 Fuel Delivery and Evaporation Lines
FUEL INJECTION (FUEL SYSTEMS)

[Link] Delivery and Evaporation Lines

A: REMOVAL

FU-03224

WARNING: (2) Remove the clip and disconnect the evapo-

Place “NO OPEN FLAMES” signs near the ration hose from the pipe.
working area. CAUTION:
CAUTION: • Be careful not to spill fuel.
• Be careful not to spill fuel. • Catch the fuel from hoses using a container
• Catch the fuel from hoses using a container or cloth.
or cloth.
1) Set the vehicle on a lift.
2) Release the fuel pressure. <Ref. to FU(H6DO)-
43, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
3) Open the fuel filler lid, and remove the fuel filler
cap. ST
4) Remove the floor mat. <Ref. to EI-72, REMOV-
AL, Floor Mat.>
5) In the engine compartment, disconnect the fuel FU-02866
delivery hoses and evaporation hose.
(1) Disconnect the quick connector of the fuel
delivery line by pushing the ST in the direction
of the arrow.
ST 42099AE000 QUICK CONNECTOR
RELEASE

FU(H6DO)-65
 Fuel Delivery and Evaporation Lines
FUEL INJECTION (FUEL SYSTEMS)

6) Lift up the vehicle. B: INSTALLATION

7) Remove the canister. <Ref. to EC(H6DO)-6, RE- Install in the reverse order of removal while being
MOVAL, Canister.> careful of the following.
8) Remove the fuel tank. <Ref. to FU(H6DO)-45,
REMOVAL, Fuel Tank.> 1. CONNECTING THE FUEL LINE QUICK
9) Remove the fuel pipe assembly. CONNECTOR
10) Disconnect the quick connector, and then dis-
CAUTION:
connect the fuel delivery hose and jet pump hose.
Make sure there is no damage or dust on the
(1) Clean the pipe and connector, if they are
connections. If necessary, clean seal surface of
covered with dust. pipe.
(2) To prevent from damaging or entering for-
eign matter, wrap the pipes and connectors with NOTE:
plastic bag etc. Use a new retainer.

(A)

(B)

FU-01333 FU-00125

(3) Hold the connector (A) and push the retainer (A) Seal surface
(B) down. (B) Pipe
(4) Pull out the connector (A) from the retainer
(B). 1) Set the new retainer (B) to connector (A).
2) Push the pipe into the connector completely.
(A)

(B)
(B)

(A) (C)
(C)

FU-00124
FU-00126
(A) Connector
(B) Retainer (A) Connector
(C) Pipe (B) Retainer
(C) Pipe

CAUTION:
• Pull the connector to ensure it is connected
securely.
• Make sure the two retainer pawls are en-
gaged in their mating positions in the connec-
tor.
• Be sure to inspect hoses and their connec-
tions for any leakage of fuel.

FU(H6DO)-66
 Fuel Delivery and Evaporation Lines
FUEL INJECTION (FUEL SYSTEMS)

3. CONNECTING THE EVAPORATION HOSE

Connect the evaporation hose to the pipe with an
overlap of 15 to 20 mm (0.59 to 0.79 in).
L = 17.5 2.5 mm (0.689 0.098 in)

(2) (3)
(A) (1)

(B) (C)
FU-00127

(A) Connector
L/2
(B) Retainer
(C) Pipe L
FU-00129
2. CONNECTING THE FUEL DELIVERY
(1) Hose
HOSE
(2) Clip
Connect the fuel delivery hose to the pipe with an
(3) Pipe
overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When the amount to be inserted is speci-
fied. C: INSPECTION
Type B: When the amount to be inserted is not 1) Make sure that there are no cracks on the fuel
specified. pipes and fuel hoses.
2) Make sure the fuel pipe and fuel hose connec-
L1: 2.5 1.5 mm (0.098 0.059 in) tions are tightened firmly.
L2: 22.5 2.5 mm (0.886 0.098 in)
CAUTION:
Be sure to inspect hoses and their connections
for any leakage of fuel.
(3) (4) (5)

(1)

L1

L2

(2)

L1 FU-03390

(1) Type A
(2) Type B
(3) Pipe
(4) Clamp
(5) Hose

FU(H6DO)-67
 Fuel System Trouble in General
FUEL INJECTION (FUEL SYSTEMS)

[Link] System Trouble in General

A: INSPECTION
Trouble and possible cause Corrective action
1. Insufficient fuel supply to injector
1) Fuel pump does not operate.
Inspect contact, especially ground, and tighten it
Defective terminal contact
securely.
Trouble in electromagnetic or electronic circuit parts Replace the faulty parts.
2) Decline of fuel pump function Replace the fuel pump.
Replace the fuel filter. Clean or replace the fuel tank if
3) Clogged fuel filter
necessary.
4) Clogged or bent fuel pipe or hose Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent air breather tube or pipe Clean, correct or replace the air breather tube or pipe.
7) Damaged diaphragm of pressure regulator Replace.
2. Leakage or blow out of fuel
1) Loose joints of the fuel pipe Retighten.
2) Cracked fuel pipe, hose and fuel tank Replace.
3) Defective welding part on the fuel tank Replace.
Clean, correct or replace the air breather tube or air vent
4) Clogged or bent air breather tube or air vent tube
tube.
3. Gasoline smell inside of compartment
Loose joints at air breather tube, air vent tube and fuel filler
1) Retighten.
pipe
2) Problem in tightening of the fuel saucer gasket air Correct or replace the gasket.
3) Inoperative fuel pump modulator or circuit Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor Replace.
2) Defective operation of fuel meter Replace.
5. Noise
1) Large operation noise or vibration of fuel pump Replace.

NOTE:
• When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.
Fill the fuel tank fully to prevent this.
• In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop to 0°C
(32°F) or less throughout the winter season, use a water removing agent in the fuel system to prevent freez-
ing fuel system and accumulating water.
• When water is accumulated in fuel filter, fill the water removing agent in the fuel tank.
• Before using water removing agent, follow the cautions noted on the bottle.

FU(H6DO)-68