Fuel Injection (Fuel Systems): Removal & Installation Subaru Forester SG

B: INSTALLATION

Install in the reverse order of removal.

Note. Replace the gasket with a new one.

Tightening torque

1. Throttle body; 22 N.m (2.2 kgf-m, 15.9 ft-lb)

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1. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-200785-S36394102122005102300000) .
2. Open the fuel flap lid, and remove the fuel filler cap.
3. Disconnect the ground cable from battery.
4. Remove the air intake duct and air cleaner case. Refer to «REMOVAL»(ref-200787-S34281602712005102300000) , Air Intake Duct and «REMOVAL»(ref-200787-S24445141242005102300000) , Air Cleaner Case.
5. Disconnect the accelerator cable (A).
6. Disconnect the cruise control cable (B). (With cruise control model)
7. Remove the power steering pump and reservoir tank from bracket. Remove the resonator chamber. Refer to «REMOVAL»(ref-200787-S04324637762005102300000) , Resonator Chamber. Remove the front side V-belt. Refer to «REMOVAL»(ref-200788-S33926247212005102300000) , V-Belt. Remove the bolts which hold power steering pipes onto the intake manifold protector. NOTE: Do not disconnect the power steering hose. Remove the bolts which install power steering pump bracket. Disconnect the connector from the power steering pump switch. Remove the power steering tank from the bracket by pulling it upwards. Place the power steering pump on the right side wheel apron.
8. Disconnect the spark plug cords from the spark plugs.
9. Disconnect the PCV hose from the intake manifold.
10. Disconnect the engine coolant hose (A) from the throttle body.
11. Disconnect the brake booster hose.
12. Remove the air cleaner case stay RH and engine harness bracket, and disconnect the engine harness connectors from the bulkhead harness connectors.
13. Disconnect the connectors from the engine coolant temperature sensor.
14. Disconnect the knock sensor connector.
15. Disconnect the connector from the crankshaft position sensor.
16. Disconnect the connector from the oil pressure switch.
17. Disconnect the connector from the camshaft position sensor.
18. Disconnect the fuel hoses from the fuel pipes. WARNING: Do not spill fuel. Catch fuel from hoses in a container or cloth.
19. Remove the bolts which hold intake manifold onto the cylinder heads.
20. Remove the intake manifold.

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1. Install the intake manifold onto the cylinder heads. NOTE: Replace the gaskets with new ones. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
2. Connect the fuel hoses.
3. Connect the connector to the camshaft position sensor.
4. Connect the connector to the oil pressure switch.
5. Connect the connector to the crankshaft position sensor.
6. Connect the knock sensor connector.
7. Connect the connectors to the engine coolant temperature sensor.
8. Install the air cleaner case stay RH and engine harness bracket, and connect the engine harness connectors to the bulkhead connectors.
9. Connect the brake booster hose.
10. Connect the engine coolant hose (A) to the throttle body.
11. Connect the PCV hose to the intake manifold.
12. Connect the spark plug cords to the spark plugs.
13. Install the power steering pump and reservoir tank to bracket. Install the reservoir tank to bracket. Connect the connector to the power steering pump switch. Tighten the bolts which install power steering pump bracket. Tightening torque: 22 N.m (2.2 kgf-m, 15.9 ft-lb) Install the power steering pipes onto the right side intake manifold protector. Install the front side V-belt. Refer to «INSTALLATION»(ref-200788-S14994437452005102300000) , V-Belt. Install the resonator chamber. Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)
14. Connect the accelerator cable (A).
15. Connect the cruise control cable (B). (With cruise control models)
16. Install the air intake duct and air cleaner case. Refer to «INSTALLATION»(ref-200787-S29216310462005102300000) , Air Intake Duct and «INSTALLATION»(ref-200787-S32054192432005102300000) , Air Cleaner Case.
17. Connect the connector to the fuel pump relay.
18. Connect the battery ground cable to battery.

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1. Disconnect the engine ground terminal from the intake manifold.
2. Disconnect the connector from the ignition coil and ignitor assembly.
3. Remove the ignition coil and ignitor assembly.
4. Remove the throttle body. Refer to «REMOVAL»(ref-200785-S33932277602005102300000) , Throttle Body.
5. Remove the air assist injector solenoid valve from the intake manifold. Refer to «REMOVAL»(ref-200785-S40669733342005102300000) , Air Assist Injector Solenoid Valve.
6. Disconnect the pressure regulator vacuum hose from the intake manifold.
7. Remove the fuel pipe protector LH.
8. Remove the fuel pipe protector RH.
9. Disconnect the connectors from the fuel injectors.
10. Disconnect the connector from the purge control solenoid valve.
11. Disconnect the air by-pass hose from the purge control solenoid valve.
12. Remove the harness bands (A) and harness bracket (B) which hold engine harness onto the intake manifold.
13. Remove the engine harness from the intake manifold.
14. Remove the purge control solenoid valve.
15. Remove the bolt which installs injector pipe on the intake manifold as shown in figure.
16. Remove the bolt which installs injector pipe on the intake manifold.
17. Remove the two bolts which hold fuel pipes on the left side of intake manifold.
18. Remove the fuel injectors. Remove the fuel injector securing clip. Remove the fuel injector while lifting up the fuel injector pipe.
19. Disconnect the air by-pass hoses from the intake manifold.
20. Loosen the clamp which holds the front left side fuel hose to the injector pipe and remove the pipe.
21. Loosen the clamp which holds the front right side fuel hose to the injector pipe and remove the pipe.
22. Remove the fuel injector pipe.
23. Remove the bolt which installs the fuel pipes on the intake manifold.
24. Remove the fuel pipe assembly and pressure regulator, from the intake manifold.

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1. Install the fuel pipe assembly and pressure regulator, etc. to the intake manifold.
2. Tighten the bolt which installs the fuel pipes on the intake manifold. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
3. Connect the right side fuel hose to the injector pipe, and tighten the clamp screw.
4. Install the fuel injector pipe.
5. Connect the left side fuel hose to the injector pipe, and tighten the clamp screw.
6. Connect the air assist hoses.
7. Install the fuel injectors. NOTE: Replace the O-rings with new ones. NOTE: Do not forget to install the fuel injector securing clip.
8. Tighten the bolt which installs the injector pipe on the intake manifold. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7ft-lb) Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)
9. Tighten the two bolts which install the fuel pipes on the left side of intake manifold. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
10. Tighten the bolt which install the injector pipe on the intake manifold. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7 ft-lb)
11. Install the purge control solenoid valve. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)
12. Connect the hoses to the purge control solenoid valve. CAUTION: Connect the evaporation hose as shown in the figure.
13. Install the engine harness onto the intake manifold. Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)
14. Connect the connectors to the fuel injectors and purge control solenoid valve.
15. Hold the engine harness by harness band (A) and harness bracket (B). NOTE: Do not use harness band on harnesses where they are supposed to be protected by the fuel pipe protector.
16. Install the fuel pipe protector RH. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)
17. Install the fuel pipe protector LH. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)
18. Connect the pressure regulator vacuum hose to the intake manifold.
19. Install the air assist injector solenoid valve to the bracket. Refer to «INSTALLATION»(ref-200785-S33577864322005102300000) , Air Assist Injector Solenoid Valve.
20. Install the throttle body to the intake manifold. Refer to «INSTALLATION»(ref-200785-S32855552742005102300000) , Throttle Body.
21. Install the ignition coil and ignition assembly.
22. Connect the connector to the ignition coil and ignitor assembly.
23. Install the engine ground terminal to the intake manifold. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)

INSTALLATION

Install in the reverse order of removal.

Tightening torque

1. 18 N.m (1.8 kgf-m, 13.0 ft-lb)

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1. Disconnect the ground cable from battery.
2. Remove the bolt which install crankshaft position sensor to the cylinder block.
3. Remove the crankshaft position sensor, and disconnect the connector from it.

Install in the reverse order of removal.

Tightening torque

1. T: 6.4 N.m (0.65 kgf-m, 4.7ft-lb)

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1. Disconnect the ground cable from battery.
2. Disconnect the connector from the camshaft position sensor.
3. Remove the bolt which installs camshaft position sensor to the camshaft position sensor support.
4. Remove the bolt which installs camshaft position sensor support to the camshaft cap LH.
5. Remove the camshaft position sensor and camshaft position sensor support as a unit.
6. Remove the camshaft position sensor itself.

Install in the reverse order of removal.

Tightening torque

1. Camshaft position sensor support; 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
2. Camshaft position sensor; 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

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1. Disconnect the ground cable from battery.
2. Remove the air cleaner case. Refer to «REMOVAL»(ref-200787-S24445141242005102300000) , Air Cleaner Case.
3. Disconnect the knock sensor connector.
4. Remove the knock sensor from the cylinder block.

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1. Install the knock sensor to the cylinder block. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) NOTE: The extraction area of the knock sensor cord must be positioned at a 60° angle relative to the engine rear.
2. Connect the knock sensor connector.
3. Install the air cleaner case. Refer to «REMOVAL»(ref-200787-S24445141242005102300000) , Air Cleaner Case.
4. Connect the battery ground cable to battery.

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1. Disconnect the ground cable from battery.
2. Disconnect the connector from the throttle position sensor.
3. Remove the throttle position sensor holding screws, and remove it.

Install in the reverse order of removal.

Tightening torque

1. 1.6 N.m (0.16 kgf-m, 1.2 ft-lb)

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1. Turn the ignition switch to OFF.
2. Loosen the throttle position sensor holding screws.
3. When using voltage meter; Take out the ECM. Turn the ignition switch to ON. Adjust the throttle position sensor to the proper position to allow the voltage signal to the ECM to be in specification. Connector & terminal / Specified voltage (B134) No. 3 (+) - (B134) No. 13 (-) / 0.45 - 0.55 V [Fully closed.] Tighten the throttle position sensor holding screws. Tightening torque: 1.6 N.m (0.16 kgf-m, 1.2 ft-lb)
4. When using Subaru Select Monitor; Turn the ignition switch to OFF. Loosen the throttle position sensor holding screws. NOTE: For detailed operation procedures, refer to the Subaru Select Monitor Operation Manual. Insert the cartridge to the Subaru Select Monitor. Connect the Subaru Select Monitor to the data link connector. Turn the ignition switch to ON, and the Subaru Select Monitor switch to ON. Select the {2. Each System Check} in Main Menu. Select the {Engine Control System} in Selection Menu. Select the {1. Current Data Display & Save} in Engine Control System Diagnosis. Select the {1.12 Data Display} in Data Display Menu. Adjust the throttle position sensor to the proper position to match with the following specifications. Condition: Throttle fully closed Throttle opening angle 0.00% Throttle sensor voltage 0.50 V Tighten the throttle position sensor holding screws. Tightening torque: 1.6 N.m (0.16 kgf-m, 1.2 ft-lb)

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1. Disconnect the ground cable from battery.
2. Disconnect the connector from the pressure sensor.
3. Remove the pressure sensor.

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Install in the reverse order of removal.

Tightening torque

1. 1.6 N.m (0.16 kgf-m, 1.2 ft-lb)

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Note. Replace the O-ring with a new one.

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1. Disconnect the ground cable from battery.
2. Disconnect the connector from the intake air temperature sensor.
3. Remove the intake air temperature sensor from air cleaner case.

Install in the reverse order of removal.

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1. Disconnect the ground cable from battery.
2. Disconnect the connector from the idle air control solenoid valve.
3. Remove the idle air control solenoid valve from the throttle body.

Install in the reverse order of removal.

Note. Always use new gasket.

Tightening torque

1. 1.6 N.m (0.16 kgf-m, 1.2 ft-lb)

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1. Disconnect the ground cable from battery.
2. Disconnect the connector from the air assist injector solenoid valve and disconnect the air by-pass hoses.
3. Remove the air assist injector solenoid valve from the intake manifold.

Install in the reverse order of removal.

Tightening torque

1. 6.4 N.m (0.65 kgf-m, 4.7ft-lb)

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1. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-200785-S36394102122005102300000) , OPERATION, Fuel.
2. Open the fuel flap lid, and remove the fuel filler cap.
3. Disconnect the ground cable from battery.
4. Remove the resonator chamber. Refer to «REMOVAL»(ref-200787-S04324637762005102300000) , Resonator Chambers.
5. Remove the spark plug cords from the spark plugs (#1 and #3 cylinders).
6. Remove the power steering pump and tank from the brackets. Remove the front side V-belt. Refer to «REMOVAL»(ref-200788-S33926247212005102300000) , V-belt. Remove the bolts which hold the power steering pipes onto the intake manifold protector. Remove the bolts which install the power steering pump to the bracket. Disconnect the connector from the power steering pump switch. Remove the power steering tank from the bracket by pulling it upwards. Place the power steering pump and tank on the right side wheel apron.
7. Remove the fuel pipe protector RH.
8. Disconnect the connector from fuel injector.
9. Remove the bolt which holds the injector pipe to the intake manifold.
10. Remove the fuel injector from the intake manifold. Remove the fuel injector securing clip. Remove the fuel injector while lifting up the fuel injector pipe.

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1. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-200785-S36394102122005102300000) , OPERATION, Fuel.
2. Open the fuel flap lid, and remove the fuel filler cap.
3. Disconnect the ground cable from battery.
4. Remove the two bolts which install the washer tank on the body.
5. Disconnect the connector from the front window washer motor.
6. Disconnect the connector from the rear gate glass washer motor.
7. Disconnect the rear window glass washer hose from the washer motor, then plug the connection with a suitable cap.
8. Move the washer tank, and secure it away from the working area.
9. Remove the spark plug cords from the spark plugs (#2 and #4 cylinders).
10. Remove the fuel pipe protector LH.
11. Disconnect the connector from the fuel injector.
12. Remove the bolt which holds the injector pipe to the intake manifold.
13. Remove the bolt which holds the fuel pipe on the left side intake manifold.
14. Remove the fuel injector from the intake manifold. Remove the fuel injector securing clip. Remove the fuel injector while lifting up the fuel injector pipe.

Install in the reverse order of removal.

Tightening torque

1. 5 N.m (0.5 kgf-m, 3.6 ft-lb)

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1. Disconnect the ground cable from battery.
2. Remove the passenger's side front side sill cover.
3. Remove the bolt which holds main bracket on the body.
4. Disconnect the connectors from the main relay.

Install in the reverse order of removal.

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1. Disconnect the ground cable from battery.
2. Remove the passenger's side front side sill cover.
3. Remove the bolt which holds fuel pump relay bracket on the body.
4. Disconnect the connector from the fuel pump.
5. Remove the fuel pump relay from the mounting bracket.

Install in the reverse order of removal.

REMOVAL

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1. Set the vehicle on the lift.
2. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-200785-S36394102122005102300000) , Fuel.
3. Drain the fuel from the fuel tank. Refer to «DRAINING FUEL»(ref-200785-S14238325112005102300000) , OPERATION, Fuel.
4. Remove the rear seat.
5. Disconnect the connector (A) of fuel tank cord to the rear harness.
6. Push the grommet (B) which holds the fuel tank cond on the floor panel into under the body.
7. Remove the rear crossmember. Refer to «REMOVAL»(ref-169444-S05338608042004120800000) , Rear Crossmember.
8. Move the clamp, and disconnect the evaporation hose from the canister.
9. Disconnect the connector from the pressure control solenoid valve.
10. Disconnect the connector from the drain valve.
11. Loosen the clamp and disconnect the fuel filler hose (A) and evaporation hose (B) from the fuel filler pipe.
12. Move the clips, and disconnect the quick connector. Refer to «REMOVAL»(ref-200785-S11750546102005102300000) , Fuel Delivery, Return and Evaporation Lines.
13. Disconnect the fuel hoses.
14. Support the fuel tank with transmission jack, remove the bolts from bands and dismount the fuel tank from the vehicle. WARNING: A helper is required to perform this work.

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1. Support the fuel tank with transmission jack and push the fuel tank harness into access hole with grommet.
2. Set the fuel tank and temporarily tighten the bolts of fuel tank bands. WARNING: A helper is required to perform this work.
3. Connect the fuel filler hose (A) and air vent hose (B).
4. Connect the fuel hoses, and hold them with clips and quick connector. Refer to «REMOVAL»(ref-200785-S11750546102005102300000) , Fuel Delivery, Return and Evaporation Lines.
5. Connect the connector to the drain valve.
6. Connect the connector to the pressure control solenoid valve.
7. Connect the evaporation hose to the canister, and hold them clamp.
8. Tighten the band mounting bolts. Tightening torque: 33 N.m (3.4 kgf-m, 25 ft-lb)
9. Install the rear crossmember. Refer to «CROSSMEMBER»(ref-169444-S30521787652004120800000) , Rear Crossmember.
10. Connect the connectors (A) to the fuel tank cord and plug the service hole with grommet (B).
11. Set the rear seat and floor mat.
12. Connect the connector to the fuel pump relay.

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1. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-200785-S36394102122005102300000) , OPERATION, Fuel.
2. Open the fuel filler flap lid and remove the filler cap.
3. Disconnect the ground cable from battery.
4. Remove the screws holding packing in place.
5. Lift-up the vehicle.
6. Remove the rear right side wheel nuts.
7. Remove the rear right side wheel.
8. Drain the fuel from the fuel tank. Set a container under the vehicle and remove the drain plug from the fuel tank.
9. Tighten the fuel drain plug. Tightening torque: 26 N.m (2.65 kgf-m, 19.2 ft-lb)
10. Remove the fuel filler pipe protector.
11. Separate the evaporation hoses from the clip of fuel filler pipe.
12. Disconnect the evaporation hoses from the pipes.
13. Remove the bolts which hold the fuel filler pipe bracket on the body.
14. Loosen the clamp and separate the fuel filler hose (A) from the fuel filler pipe.
15. Move the clip and separate the evaporation hose (B).
16. Remove the fuel filler pipe to under side of the vehicle.
17. Remove the evaporation pipe together with clip from the body.

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1. Hold the fuel filler flap open.
2. Set the fuel saucer (A) with rubber packing (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. NOTE: If the edges of rubber packing are folded toward the inside, straighten it with a screwdriver.
4. Install the evaporation pipe.
5. Connect the evaporation hose to the pipe.
6. Insert the fuel filler hose (A) approximately 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe and tighten the clamp. CAUTION: Do not allow clips to touch evaporation hose (B) and rear suspension crossmember.
7. Insert the evaporation hose approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe and hold the clip. L = 27.5+/-2.5 mm (1.083+/-0.098 in)
8. Tighten the bolt which holds the fuel filler pipe bracket on the body. Tightening torque: 7.5 N.m (0.75 kgf-m, 5.4 ft-lb)
9. Secure the evaporation hose to clip of fuel filler pipe.
10. Install the fuel filler pipe protector.
11. Install the rear right wheel.
12. Lower the vehicle.
13. Tighten the wheel nuts.
14. Connect the connector to the fuel pump relay.
15. Connect the battery ground terminal.

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1. Move the clip, and disconnect the evaporation hose from the joint pipe.
2. Remove the bolt which installs the joint pipe on the fuel filler pipe.
3. Disconnect the evaporation hose from the fuel filler pipe.
4. Remove the shut valve from the fuel filler pipe. Refer to «REMOVAL»(ref-200786-S16759529292005102300000) , Shut Valve.

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1. Install the shut valve on the fuel filler pipe. Refer to «INSTALLATION»(ref-200786-S10309057842005102300000) , Shut Valve.
2. Connect the evaporation hose to the fuel filler pipe.
3. Connect the evaporation hose to the evaporation pipe.
4. Install the evaporation pipe to the fuel filler pipe.

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Note. Fuel pump assembly consists of fuel pump and fuel level sensor.

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1. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-200785-S36394102122005102300000) , OPERATION, Fuel.
2. Open the fuel filler flap lid and remove the fuel filler cap.
3. Disconnect the ground cable from battery.
4. Lift-up the vehicle.
5. Drain the fuel from the fuel tank. Set a container under the vehicle and remove the drain plug from the fuel tank.
6. Tighten the fuel drain plug. Tightening torque: 26 N.m (2.65 kgf-m, 19.2 ft-lb)
7. Raise the rear seat and turn the floor mat up.
8. Remove the access hole lid.
9. Disconnect the connector from the fuel pump.
10. Disconnect the quick connector and then disconnect the fuel delivery hose. Refer to «REMOVAL»(ref-200785-S11750546102005102300000) , Fuel Delivery, Return and Evaporation Lines.
11. Move the clip and then disconnect the fuel return hose (A) and jet pump hose (B).
12. Remove the nuts which install the fuel pump assembly onto the fuel tank.
13. Take off the fuel pump assembly from the fuel tank.

Install in the reverse order of removal. Do the following

Note. Replace the gasket with a new one.

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1. Ensure the sealing portion is free from fuel or foreign particles before installation.
2. Tighten the nuts in alphabetical sequence shown in figure to specified torque. Tightening torque: 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

Note. Fuel level sensor is built in fuel pump assembly.

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1. Remove the fuel pump assembly. Refer to «REMOVAL»(ref-200785-S32527592732005102300000) , Fuel Pump.
2. Disconnect the connector from the fuel pump bracket.
3. Remove the bolt which installs the fuel level sensor on the mounting bracket.

Install in the reverse order of removal.

Tightening torque

1. 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

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1. Disconnect the ground cable from battery.
2. Lift-up the vehicle.
3. Drain the fuel from the fuel tank. Set a container under the vehicle and remove the drain plug from the fuel tank.
4. Tighten the fuel drain plug. Tightening torque: 26 N.m (2.65 kgf-m, 19.2 ft-lb)
5. Remove the rear seat.
6. Remove the service hole cover.
7. Disconnect the connector from the fuel sub meter.
8. Disconnect the fuel jet pump hose.
9. Remove the bolts which install the fuel sub meter unit on the fuel tank.
10. Remove the fuel sub meter unit.

Install in the reverse order of removal.

Tightening torque

1. 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

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1. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-200785-S36394102122005102300000) , OPERATION, Fuel.
2. Disconnect the fuel delivery hoses from the fuel filter.
3. Remove the filter from the holder.

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1. Install in the reverse order of removal.
2. Tighten the hose clamp screws. Tightening torque: 1.25 N.m (0.13 kgf-m, 0.94 ft-lb)

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1. Remove the fuel tank. Refer to «REMOVAL»(ref-200785-S17967819082005102300000) , Fuel Tank.
2. Remove the protect cover.
3. Move the clip and disconnect the evaporation hose from the fuel cut valve.
4. Remove the bolts which install the fuel cut valve.

Install in the reverse order of removal.

Tightening torque

1. 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

Scheme 224

1. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-200785-S36394102122005102300000) , OPERATION, Fuel.
2. Remove the fuel damper valve from the fuel return line.

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Install in the reverse order of removal.

Tightening torque

1. 1.25 N.m (0.13 kgf-m, 0.94 ft-lb)

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1. Set the vehicle on the lift.
2. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-200785-S36394102122005102300000) , OPERATION, Fuel.
3. Open the fuel filler flap lid and remove the fuel filler cap.
4. Remove the floor mat. Refer to «REMOVAL»(ref-200811-S14593490662005102300000) , Floor Mat.
5. Remove the fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses.
6. In engine compartment, detach the fuel delivery hoses, return hoses and evaporation hose.
7. Lift-up the vehicle.
8. Separate the quick connector on the fuel delivery and return line. Clean the pipe and connector, if they are covered with dust. Hold the connector (A) and push retainer (B) down. Pull out the connector (A) from retainer (B). CAUTION: Replace retainer with new ones.

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

1. Connect the quick connector on fuel delivery line. CAUTION: Always use a new retainer. Make sure that the connected portion is not damaged or has dust. If necessary, clean seal surface of pipe. Set the new retainer (B) to connector (A). Push the pipe into the connector completely. NOTE: At this time, two clicking sounds are heard. CAUTION: Pull the connector to ensure it is connected securely. Ensure the two retainer pawls are engaged in their mating positions in the connector. Be sure to inspect hoses and their connections for any leakage of fuel.
2. Connect the fuel delivery hose to the pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in). Type A: When the fitting length is specified. Type B: When the fitting length is not specified. l :2.5+/-1.5 mm (0.098+/-0.059 in) L: 22.5+/-2.5 mm (0.886+/-0.098 in)
3. Connect the return hose and evaporation hose to pipe by approx. 15 mm (0.59 in) from the hose end. Fuel return hose: L = 22.5+/-2.5 mm (0.885+/-0.098 in) Fuel evaporation hose: L = 17.5+/-2.5 mm (0.689+/-0.098 in) CAUTION: Be sure to inspect hoses and their connections for any leakage of fuel.