Fuel Injection System: Overview Subaru BRZ ZC

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1. Precautions before work Before performing the work related to the fuel system, perform the fuel spill prevention procedure and disconnect the negative terminal from the battery. (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) Be sure not to perform the work related to the fuel system near open flames. Also be sure not to smoke during the work. Keep rubber and leather parts away from gasoline.
2. Fuel spill prevention procedure CAUTION: Perform this procedure when the engine coolant temperature is 60°C {140°F} or less. Always perform the fuel spill prevention procedure before removing the fuel system parts. Since a small amount of residue pressure exists in the fuel line after the fuel spill prevention procedure, prevent the fuel from splashing when disconnecting the fuel line. Remove the relay block cover UPR. Remove the fuel pump fuse from the engine compartment relay block. Start the engine. Turn the ignition to OFF after the engine stalls by itself. Crank the engine again and check that it does not start. NOTE: Since a diagnostic code may be detected, check/clear the diagnostic code after the work is completed. (Refer to «CHECKING/CLEARING DTC»(/subaru/brz/zc-2012-2016/remont/testing-diagnostics/#engine-control-system-diagnostics) ) Remove the fuel tank cap to release the pressure in the fuel tank. Disconnect the battery ground terminal. (Refer to «WORKING PRECAUTIONS AND NOTES»(ref-619149-S01292846772014053000000) ) Install the fuel pump fuse. Install the relay block cover UPR.
3. Fuel system (quick type A) When disconnecting the fuel tube connector (quick type A), adhere to the following precautions. Release the two claws in the retainer of fuel tube connector and push down the retainer as shown in the figure to disconnect the fuel tube connector from the pipe. If the fuel tube connector is seized on the pipe, hold the pipe and push/pull the fuel tube connector to release it, and then disconnect the fuel tube connector. CAUTION: Before starting the work, remove the foreign matters such as dirt on the fuel tube connector. Since the fuel tube connector seals the fuel tube connector and pipe with the O-ring, pay special attention to the damage and foreign matters on the connection. Never use any tools. After the fuel tube is disconnected, protect the connection with a vinyl bag. If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it, and then pull out it. When connecting the fuel tube connector (quick type A), adhere to the following precautions. Align the axis of fuel tube connector and the axis of pipe, then push in the fuel tube connector and push up the retainer. After the fuel tube connector is connected, pull the fuel tube connector and pipe to ensure they are connected securely.
4. Fuel system (quick type B) When disconnecting the fuel tube connector (quick type B) using the SST, adhere to the following precautions. Before disconnecting the fuel tube connector, check the fuel tube connector and pipe for dirt or dust. If dirt or dust is found, clean them. Attach the SST to the pipe. Push in the SST to disconnect the fuel tube connector from the pipe. SST 42099AE000 CAUTION: Hold the holding portion of the connector to pull out it in axial direction. If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it with the SST pushed in, and then pull out fuel tube connector. When disconnecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part. Catch the fuel from the tube using a container to prevent it from splashing. After disconnecting the fuel tube, check the seal surface of pipe for dirt or dust. Make sure that the top hat or O-ring does not fall off. Protect the disconnected fuel tube connector and pipe with vinyl bags. CAUTION: When reusing the retainer, do not remove the retainer from the connector. Do not damage the fuel tube connector and pipe or allow foreign matter to enter the pipe. When disconnecting the fuel tube connector (quick type B) without the SST, adhere to the following precautions. Before disconnecting the fuel tube connector, check the fuel tube connector and pipe for dirt or dust. If dirt or dust is found, clean them. Push the retainer in the direction of the arrow, disconnect the fuel tube connector from pipe. CAUTION: Hold the holding portion of the connector to pull out it in axial direction. If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it with the retainer pushed in, and then pull out fuel tube connector. When disconnecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part. Catch the fuel from the tube using a container to prevent it from splashing. After disconnecting the fuel tube, check the seal surface of pipe for dirt or dust. Make sure that the top hat or O-ring does not fall off. Protect the disconnected fuel tube connector and pipe with vinyl bags. CAUTION: When reusing the retainer, do not remove the retainer from the pipe. Do not damage the fuel tube connector and pipe or allow foreign matter to enter the pipe. When connecting the fuel tube connector (quick type B), adhere to the following precautions. Make sure there are no damage or dust on connections. If necessary, clean the seal surface of pipe. When reusing the retainer, make sure that neither damage nor deformation exist on the retainer. If it is faulty, replace it with a new retainer. Align the axis of fuel tube connector and the axis of pipe, push in the fuel tube connector until a clicking sound is heard from the retainer. CAUTION: Hold the holding portion of the connector to push in it in axial direction. When connecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part. After the fuel tube connector is connected, make sure that the fuel tube connector and pipe are connected securely. CAUTION: Make sure that the two retainer pawls are engaged in their mating positions in the quick connector. Make sure that there are no fuel leakages from the fuel tube and its connection.
5. Fuel system (quick type C) When disconnecting a fuel pressure line, a large amount of gasoline will spill out. Perform the following procedure: Discharge fuel system pressure. Put a container under the connection. Disconnect the fuel pump tube. Drain the fuel remaining inside the fuel pump tube into the container. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination. Observe these precautions when connecting the fuel tube connector. Attach SST to the fuel pipe. SST 42099AE000 Insert SST in the fuel tube connector side, and remove the fuel tube from the fuel pipe. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination. Observe these precautions when connecting the fuel tube connector. Check for damage or foreign matter on the connected part of the fuel pipe. Align the fuel tube connector axis with the fuel pipe axis, and push the fuel tube connector in until the retainer makes a clicking sound. After connecting the fuel tube connector, pull the fuel tube connector and pipe, and then push them to check that they are connected firmly. NOTE: Be sure to always finish checking the fuel pipe connections by pushing.
6. Fuel system (evaporation hose connection) Connect the evaporation hose as shown in the figure. CAUTION: If there is no spool or stopper, connect the hose by inserting it into the pipe by 15 to 20 mm {0.591 to 0.787 in}.

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1. Fuel pressure check (low-pressure side) Fuel pressure gauge installation (port injection side) Perform the fuel spill prevention procedure. (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) CAUTION: Since a small amount of residue pressure exists in the fuel line after the fuel spill prevention procedure, prevent the fuel from splashing when disconnecting the fuel line. Disconnect the fuel hose NO. 1 with the SST. SST 42099AE000 Install the fuel pressure gauge to the vehicle. Wipe off any spilt fuel. Fuel pressure gauge installation (cylinder injection side) Perform the fuel spill prevention procedure. (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) CAUTION: Since a small amount of residue pressure exists in the fuel line after the fuel spill prevention procedure, prevent the fuel from splashing when disconnecting the fuel line. Disconnect the fuel hose NO. 2 with the SST. SST 42099AE000 Install the fuel pressure gauge to the vehicle. Wipe off any spilt gasoline. Fuel pressure check Measure the fuel pressure while engine idling after warming up the engine. Standard value: 350 to 500 kPa {4.0 to 5.0 kgf/cm 2 } {51 to 72 psi} Perform the fuel spill prevention procedure. (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) Fuel pressure gauge removal Be careful not to splash gasoline and remove the fuel pressure gauge. Connect the fuel hoses NO. 1 and NO. 2.
2. Fuel pressure check (high pressure side) Connect the SSM3 to the DLC. Turn the ignition switch to ON. Start the engine and check the value in [Data monitor] -->[Fuel Rail Pressure] at idling. Standard value: 3.5 to 4.5 MPa {35.7 to 45.9 kgf/cm 2 } {507.5 to 652.5 psi}
3. «DTC B1010 INTEGRATED UNIT SYSTEM ERROR»(ref-619154-S11424056422014053000000) Connect the SSM3 to the DLC. Start the engine, select [Active Test] -->[D-4S (power balance)] according to the screen display and select [Port injection] or [Cylinder injection]. Check the idling status after the injection to the executed cylinder of '#1 to #4' has been stopped. Criteria: The idle speed shall vary. CAUTION: Only one cylinder can be tested at a time and multiple cylinders shall not be tested.
4. Fuel leakage check Make sure that there are no fuel leakages from the fuel system with the fuel pressure.

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1. Fuel injector assembly (Cylinder injection side)
2. Fuel injector assembly (Port injection side)

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1. Fuel spill prevention procedure (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) )
2. Disconnection of the battery ground terminal (Refer to «WORKING PRECAUTIONS AND NOTES»(ref-619149-S01292846772014053000000) )
3. Chamber assembly removal (Refer to «REMOVAL»(ref-619189-S11526614902014053000000) )
4. Removal of injector driver (Refer to «REMOVAL»(ref-619185-S39930494242014053000000) )
5. Intake manifold protector (bank 1 side) removal Release the four clamps and disconnect the wiring harness. Remove the 2 bolts, and remove the intake manifold protector (bank 1 side).
6. Fuel hose NO. 1 disconnection Put an alignment mark on the fuel hose No. 1. Disconnect the fuel hose NO. 1 with the SST. (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) SST 42099AE000
7. Fuel hose NO. 2 disconnection Put an alignment mark on the fuel hose No. 2. Disconnect the fuel hose NO. 2 with the SST. (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) SST 42099AE000
8. Purge hose disconnection Move the hose clamp and disconnect the purge hose.
9. Intake manifold protector (bank 2 side) removal Remove the bolt and disconnect the wiring harness clamp bracket. Remove the 2 bolts, and remove the intake manifold protector (bank 2 side).
10. Fuel delivery pipe (bank 2 side) removal Disconnect the two fuel injector assembly connectors. Release the clamp and disconnect the wiring harness. Disconnect the fuel pump connector. Disconnect the fuel delivery pipe NO. 3 from the fuel delivery pipe (bank 2 side). (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) Remove the 2 bolts and remove the fuel delivery pipe (bank 2 side) by pulling up it along the axis line of fuel injector assembly.
11. Fuel delivery pipe (bank 1 side) removal Disconnect the two fuel injector assembly connectors. Release the clamp and disconnect the wiring harness. Disconnect the fuel delivery pipe NO. 3 from the fuel delivery pipe (bank 1 side). (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) Remove the 2 bolts and remove the fuel delivery pipe (bank 1 side) by pulling up it along the axis line of fuel injector assembly.
12. Fuel injector assembly removal Remove the fuel injector assembly from the fuel delivery pipe. CAUTION: When the fuel injector assembly is reinstalled without replacing it, identify it with a tag etc. marked with the cylinder number. Remove the two O-rings from the fuel injector assembly.

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1. Fuel injector assembly installation (low pressure side) Apply gasoline to two new O-rings and install them to the fuel injector assembly. CAUTION: Make sure that there are no damage or foreign matter in the O-ring grooves of fuel injector assembly. Install the fuel injector assembly to the fuel delivery pipe. CAUTION: Make sure that there are no foreign matter or scratches on the insertion portion of fuel delivery pipe. Be careful not to twist the O-ring. After the fuel delivery pipe is installed, make sure that it can be rotated relatively lightly. If it cannot be rotated lightly, remove the fuel injector assembly and repeat the work after replacing the O-rings with new ones.
2. Fuel delivery pipe (bank 1 side) installation Install the fuel delivery pipe (bank 1) to the intake manifold by moving it along the axis line of fuel injector assembly. Tighten the two bolts. Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf} Connect the fuel delivery pipe NO. 3 to the fuel delivery pipe (bank 1 side). (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) Connect the injector assembly connector to engage the clamp.
3. Fuel delivery pipe (bank 2 side) installation Install the fuel delivery pipe (bank 2) to the intake manifold by moving it along the axis line of fuel injector assembly. Tighten the two bolts. Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf} Connect the fuel pump connector. Connect the fuel delivery pipe NO. 3 to the fuel delivery pipe (bank 2 side). (Refer to «PRECAUTIONS»(ref-619185-S19706191162014053000000) ) Connect the fuel injector assembly connector to engage the clamp.
4. Intake manifold protector (bank 2 side) installation Using 2 bolts, install the intake manifold protector (bank 2 side). Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf} Install the wiring harness clamp bracket with the bolt. Standard value: T=11N.m {112kgf.cm} {8.1ft.lbf}
5. Purge hose connection Connect the purge hose and secure it with the hose clamp.
6. Fuel hose NO. 2 connection
7. Fuel hose NO. 1 connection
8. Intake manifold protector (bank 1 side) installation Using 2 bolts, install the intake manifold protector (bank 1 side). Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf} Engage the four clamps and connect the wiring harness.
9. Installation of injector driver (Refer to «INSTALLATION»(ref-619185-S04023132172014053000000) )
10. Chamber assembly installation (Refer to «INSTALLATION»(ref-619189-S23563911992014053000000) )
11. Connection of the battery ground terminal Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}

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1. Fuel injector assembly check CAUTION: This procedure must be used only when judging short circuit and open circuit. It cannot be used for judging defective operation. Resistance check Measure the resistance between the terminals. RESISTANCE Inspection terminals Inspection conditions Standard value 1 - 2 20°C {68°F} 12 ohms

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1. Intake manifold removal (Refer to «DISASSEMBLY»(ref-619189-S01395914062014053000000) )
2. Fuel delivery pipe NO. 2 removal Remove the fuel delivery pipe NO. 2. CAUTION: When removing the fuel delivery pipe NO. 2, pull it straight out so that the seal surface of fuel delivery pipe LH is not damaged.
3. Fuel delivery pipe removal Remove the 3 bolts. Remove the fuel delivery pipe.
4. Fuel delivery pipe (bank 2 side) removal Disconnect the two fuel injector connectors. Remove the two bolts and remove fuel delivery pipe (bank 2 side).
5. Fuel delivery pipe (bank 1 side) removal Disconnect the fuel pressure sensor connector and two fuel injector connectors. Remove the two bolts and remove fuel delivery pipe (bank 1 side).
6. Fuel injector assembly removal Remove the fuel injector assembly from the fuel delivery pipes (bank 2 side) and (bank 1 side). CAUTION: If the tip of fuel injector assembly is bumped or dropped, replace the fuel injector assembly with a new one. When removing the injector, pull it straight out so that the seal surfaces of fuel delivery pipes (bank 2 side) and (bank 1 side) are not damaged. Identify the removed fuel injector assembly with a tag etc. marked with the cylinder number. Remove the fuel injector holder from the fuel injector assembly. Remove the C-ring and fuel injector insulator. Remove the back-up ring NO. 1. Remove the fuel injector seal and back-up ring NO. 2.
7. Fuel injector seal removal Hold the fuel injector seal and widen it a little. CAUTION: Be careful not to hold the fuel injector seal too strongly in order to protect the injector groove from scratches. If the tip of fuel injector assembly is bumped or dropped, replace the fuel injector assembly with a new one.

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1. Fuel injector seal installation Use the engine conditioner to remove the carbon on engine oil on the side surface and seal groove of injector shown in the figure. CAUTION: Do not clean the tip portion. Do not use a wire brush etc. If the tip of fuel injector assembly is bumped or dropped, replace the fuel injector assembly with a new one. Apply engine oil to the inner periphery of SST (guide) and set it on the injector so that the taper surface faces toward the tip side of injector. SST 09260-39020 Install a new fuel injector seal to the SST (holder). SST 09260-39020 CAUTION: When setting the fuel injector seal on the SST (holder), the seal is stretched and it is difficult to correct if the seal is set at an angle. Set the SST (holder) with the fuel injector seal to the tip of injector and push down the fuel injector seal with fingers to install it in the injector groove shown in the figure. SST 09260-39020 CAUTION: Make sure the fuel injector seal is completely fitted in the groove for its entire circumference. While holding the fuel injector seal (connector side) lightly with the SST (holder), pull up the SST (guide) toward the injector tip side slowly and seat the fuel injector seal in the injector groove. SST 09260-39020 CAUTION: Be careful not to pinch the fuel injector seal between the SST (guide) and injector groove. If it is pinched, replace it with a new one. Pull up the SST (guide) toward the injector tip side slowly and hold the SST for 5 sec. or more when the fuel injector seal on the connector side reaches to the straight portion of SST (guide) in order to correct the fuel injector seal. SST 09260-39020 CAUTION: Be careful not to pinch the fuel injector seal between the SST (guide) and injector groove. If it is pinched, replace it with a new one. NOTE: A rough indication of the straight portion is the position where the bottom of fuel injector seal aligns with the bottom of SST (guide). When the SST (guide) cannot be pulled up because it is stuck, pull up it gradually by rotating the SST (guide) to the left and right slowly. After the fuel injector seal is installed, make sure that there is no scratches on the seal, crushing of the seal, or protrusion of the seal from the seal groove. CAUTION: When there is any scratches on the fuel injector seal, crushing of it, or protrusion of it from the seal groove, replace it with a new part.
2. Fuel injector assembly installation CAUTION: If the tip of fuel injector assembly is bumped or dropped, replace the fuel injector assembly with a new one. Install a new back-up ring NO. 2, new fuel injector seal and new back-up ring NO. 1 as shown in the figure. CAUTION: There must be no foreign matter, scratches, etc. in the fuel injector seal groove of injector. Be careful not to mix up the directions of back-up springs NO. 1 and NO. 2. Be careful not to mix up the installation order of back-up spring and fuel injector seal. There must be no running on or widening of back-up ring gap portion as shown in the figure. After the installation, there must be no foreign matter, scratches, etc. in the fuel injector seal. Install a new fuel injector insulator and new O-ring. CAUTION: Install the fuel injector insulator in the direction as shown in the figure. Install the fuel injector holder to the fuel injector assembly. Apply new engine oil to the chamfered portions of injector insertion holes of the fuel delivery pipes (bank 2 side) and (bank 1 side). Align the protrusion of fuel injector holder to the arrest holes of fuel delivery pipes (bank 2 side) and (bank 1 side) to install the fuel injector holder. CAUTION: There must be no foreign matter, scratches, etc. inside the injector insertion holes of the fuel delivery pipes (bank 2 side) and (bank 1 side). There must be no gasoline on the fuel injector seal and inside the attachment hole. Insert the injector straight to the fuel delivery pipes (bank 2 side) and (bank 1 side) without tilting it. There must be no gap between the high pressure side fuel injector pipe and fuel injector holder. When replacing the fuel injector assembly, install a new assembly with the same flow stratified number.
3. Fuel delivery pipe (bank 2 side) installation Install the fuel delivery pipe (bank 2 side) with the two bolts. Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf} Connect the two fuel injector connectors.
4. Fuel delivery pipe (bank 1 side) installation Install the fuel delivery pipe (bank 1 side) with the two bolts. Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf} Connect the two fuel injector connectors and fuel pressure sensor connector.
5. Fuel delivery pipe installation Temporarily install a new fuel delivery pipe. Temporarily install the fuel delivery pipe with the three bolts. Tighten the three bolts. Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf} Tighten the fuel delivery pipe. Standard value: T=35N.m {357kgf.cm} {25.8ft.lbf}
6. Fuel delivery pipe NO. 2 installation Temporarily install a new fuel delivery pipe NO. 2. Tighten the fuel delivery pipe NO. 2. Standard value: T=35N.m {357kgf.cm} {25.8ft.lbf}
7. Intake manifold installation (Refer to «INSTALLATION»(ref-619189-S11634536132014053000000) )

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1. Fuel injector assembly check CAUTION: This procedure must be used only when judging short circuit and open circuit. It cannot be used for judging defective operation. Resistance check Measure the resistance between the terminals. RESISTANCE Inspection terminals Inspection conditions Standard value 1 - 2 20°C {68°F} 1.9 ohms

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1. Intake manifold removal (Refer to «DISASSEMBLY»(ref-619189-S01395914062014053000000) )
2. Fuel delivery pipe removal Remove the 3 bolts. Remove the fuel delivery pipe.
3. Fuel delivery pipe (bank 1 side) removal Disconnect the fuel pressure sensor connector and two fuel injector connectors. Remove the two bolts and remove fuel delivery pipe (bank 1 side).
4. Fuel pressure sensor removal Remove the fuel pressure sensor from the fuel delivery pipe (bank 1 side).
5. Fuel injector assembly removal (Refer to «REMOVAL»(ref-619185-S26498359542014053000000) )

See also:
• CHECKING/CLEARING DTC
• ON-VEHICLE INSPECTION