Fuel System - Dohc/tc Subaru Impreza WRX GD/GG рестайлинг

GENERAL DESCRIPTION

Note. For information on fuel system testing, see SELF-DIAGNOSTICS - 2.0L and SYSTEM & COMPONENT TESTING . For removal and installation of emissions related components, canister, drain valve, sensors etc. See REMOVAL & INSTALLATION - ENGINE PERFORMANCE .

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CAUTION

1. Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust or dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
5. Be careful not to burn your hands, because each part on the vehicle is hot after running.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or safety stands at the specified points.
8. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.
9. Place "NO FIRE" signs near the working area.
10. Be careful not to spill fuel on the floor.

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FUEL SYSTEM SERVICING

Note. For additional information on air cleaner case and intercooler removal and installation, see AIR INTAKE SYSTEM , Engine Mechanical.

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1. Lower the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__releasing-of-fuel-pressure) , OPERATION, Fuel.
2. Open the fuel filler flap lid and remove fuel filler cap.
3. Disconnect the ground cable from battery.
4. Remove the intake manifold, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4dotc) , Intake Manifold.
5. Remove the fuel pipe protector RH.
6. Disconnect the connector from the fuel injector.
7. Remove the bolts which holds the injector pipe to intake manifold.
8. Remove the fuel injector while lifting up the fuel injector pipe.

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1. Lower the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__releasing-of-fuel-pressure) , OPERATION, Fuel.
2. Open the fuel filler flap lid and remove fuel filler cap.
3. Disconnect the ground cable from battery.
4. Remove the intake manifold, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4dotc) , Intake Manifold.
5. Remove the fuel pipe protector LH.
6. Disconnect the connector from the fuel injector.
7. Remove the bolts which holds the injector pipe to intake manifold.
8. Remove the fuel injector while lifting up the fuel injector pipe.

RH SIDE

Install in the reverse order of removal.

Note. Replace the O-ring and insulators with new ones.

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1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb)

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1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb)

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1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb)

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LH SIDE

Install in the reverse order of removal.

Note. Replace the O-ring and insulators with new ones.

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1. Tightening torque: 4.9 N.m (0.5 kgf-m, 3.6 ft-lb)

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1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb)

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1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb)

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1. Tightening torque: 19 N.m (1.94 kgf-m, 13.7 ft-lb)

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1. Disconnect the battery ground cable.
2. Remove the lower inner trim of passenger side. See «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/exteriorinterior-trim/#exteriorinterior-trim) , Lower Inner Trim.
3. Detach the floor mat of the front passenger seat.
4. Remove the protect cover.
5. Remove the nuts (A) which hold ECM to the bracket.
6. Remove the clip (B) from the bracket.
7. Disconnect the ECM connectors and take out the ECM.

INSTALLATION

Install in the reverse order of removal.

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

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

Install in the reverse order of removal.

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1. Disconnect the battery ground cable.
2. Remove the rear quarter trim, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/exteriorinterior-trim/#exteriorinterior-trim) , Rear Quarter Trim.
3. Disconnect the connector from the fuel pump control unit.
4. Remove the fuel pump control unit.

Install in the reverse order of removal.

RELEASING OF FUEL PRESSURE

Scheme 169

1. Disconnect the connector from the fuel pump relay.
2. Start the engine and run it until it stalls.
3. After the engine stalls, crank it for five more seconds.
4. Turn the ignition switch to OFF.

DRAINING FUEL

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1. Set the vehicle on the lift.
2. Disconnect the battery ground cable.
3. Lift-up the vehicle.
4. Drain the fuel from the fuel tank. Set a container under the vehicle and remove drain plugs from the fuel tank.
5. Tighten the fuel drain plugs. Tightening torque: 26 N.m (2.65 kgf-m, 19.2 ft-lb)

REMOVAL

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1. Set the vehicle on the lift.
2. Lower the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__releasing-of-fuel-pressure) , OPERATION, Fuel.
3. Drain the fuel from the fuel tank, see «DRAINING FUEL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__draining-fuel) , 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 cord on floor panel into under the body.
7. Remove the rear crossmember, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/suspension-rear/#rear-suspension) , Rear Crossmember.
8. Move the clamp, and disconnect the evaporation hose from 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 air vent hose (B) from fuel filler pipe and air vent pipe.
12. Move the clips, and disconnect the quick connector. See «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc) , 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 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 the 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 and air vent hose.
4. Connect the fuel hoses, and hold them with clips and quick connector. See «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc) , 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 with clamp.
8. Tighten the band mounting bolts. Tightening torque: 33 N.m (3.4 kgf-m, 25 ft-lb)
9. Install the rear crossmember, see «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/suspension-rear/#rear-suspension) , Rear Crossmember.
10. Connect the connector (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.

INSPECTION

1. Make sure there are no cracks, holes, or other damage on the fuel tank.
2. Make sure that the fuel hoses and fuel pipes are not cracked and that connections are tight.

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1. Lower the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__releasing-of-fuel-pressure) , OPERATION, Fuel.
2. Open the fuel filler flap lid and remove the filler cap.
3. Disconnect the battery ground cable.
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 fuel tank, see «DRAINING FUEL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__draining-fuel) , Fuel. Set a container under the vehicle and remove the drain plugs from fuel tank.
9. Tighten the fuel drain plugs and then install the front right side tank cover. 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 fuel filler pipe bracket on the body.
14. Loosen the clamp and separate the fuel filler hose (A) from 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 air vent 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 the 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 edges of rubber packing are folded toward the inside, straighten it with a screwdriver.
4. Install the evaporation pipes.
5. Connect the evaporation hose to pipes.
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 air vent hose (B) and rear suspension crossmember.
7. Insert the air vent hose approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of air vent pipe and hold clip. L = 27.5 +/- 2.5 mm (1.083 +/- 0.098 in)
8. Tighten the bolt which holds fuel filler pipe bracket on the body. Tightening torque: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
9. Tighten the bolts which hold evaporation hoses onto the 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 joint pipe.
2. Remove the bolt which installs the joint pipe on fuel filler pipe.
3. Disconnect the evaporation hose from the fuel filler pipe.
4. Remove the shut valve from the fuel filler pipe, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__removal-installation) , Shut Valve.

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1. Install the shut valve on the fuel filler pipe, see «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__removal-installation) , 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.

REMOVAL & INSTALLATION

For removal and installation procedures (Scheme 216)

1. Tightening torque: 4.5 N.m (0.46 kgf-m, 3.3 ft-lb)

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

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1. Lower the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__releasing-of-fuel-pressure) , OPERATION, Fuel.
2. Open the fuel filler flap lid and remove the fuel filler cap.
3. Disconnect the battery ground cable.
4. Lift-up the vehicle.
5. Drain the fuel from fuel tank, see «DRAINING FUEL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__draining-fuel) , Fuel. Set a container under the vehicle and remove the drain plugs from fuel tank.
6. Tighten the fuel drain plugs. 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 (A). See «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc) Fuel Delivery, Return and Evaporation Lines.
11. Move the clips, and then disconnect the fuel return hose (A) and jet pump hose (B).
12. Remove the nuts which installs the fuel pump assembly onto fuel tank.
13. Take off the fuel pump assembly from the fuel tank.

Install in the reverse order of removal. Do the following

1. Always use new gaskets.
2. Ensure the sealing portion is free from fuel or foreign particles before installation.
3. Tighten the nuts in alphabetical sequence shown in figure to specified torque.

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

Scheme 224

Connect the lead harness to the connector terminal of fuel pump and apply battery power supply to check whether the pump operate.

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

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1. Remove the fuel pump assembly, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc) , Fuel Pump.
2. Disconnect the connector from the fuel pump bracket.
3. Remove the bolt which installs the fuel level sensor on mounting bracket.

Install in the reverse order of removal.

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1. Disconnect the battery ground cable.
2. Lift-up the vehicle.
3. Drain the fuel from the fuel tank, see «DRAINING FUEL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__draining-fuel) , Fuel. Set a container under the vehicle and remove drain plugs from fuel tank.
4. Tighten the fuel drain plugs. 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 installs the fuel sub meter unit on fuel tank.
10. Remove the fuel sub meter unit.

Install in the reverse order of removal.

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

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1. Lower the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__releasing-of-fuel-pressure) , OPERATION, Fuel.
2. Disconnect the fuel delivery hoses from the fuel filter.
3. Remove the filter from the holder.

1. Install in the reverse order of removal.
2. Tighten the hose clamp screws.

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

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1. Check the inside of fuel filter for dirt and water sediment.
2. If it is clogged, or if replacement interval has been reached, replace it.
3. If water is found in it, shake and expel the water from the inlet port.

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1. Remove the fuel tank, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc) , Fuel Tank.
2. Remove the protect cover.
3. Move the clip and disconnect the evaporation hose from fuel cut valve.
4. Remove the bolts which installs the fuel cut valve.

Install in the reverse order of removal.

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

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1. Lower the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__releasing-of-fuel-pressure) , OPERATION, Fuel.
2. Remove the fuel damper valve from the fuel return line.

Install in the reverse order of removal.

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

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1. Set the vehicle on the lift.
2. Lower the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-dohctc__releasing-of-fuel-pressure) , OPERATION, Fuel.
3. Open the fuel filler flap lid and remove the fuel filler cap.
4. Remove the floor mat, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/exteriorinterior-trim/#exteriorinterior-trim) 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 hose (A), return hose (B) and evaporation hose (C).
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).

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1. Connect the quick connector on the 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. I: 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 the pipe by approximately 15 mm (0.59 in) from the hose end.

Fuel return hose

1. L = 22.5 +/- 2.5 mm (0.885 +/- 0.098 in)

Fuel evaporation hose

1. L = 17.5 +/- 2.5 mm (0.689 +/- 0.098 in)

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1. Make sure that there are no cracks on the fuel pipes and fuel hoses.
2. Make sure that the fuel pipe and fuel hose connections are tight.

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Note. When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.

To prevent water condensation.

1. Top off the fuel tank or drain the fuel completely.
2. Drain the water condensation from the fuel filter. Refilling the fuel tank. Refill the fuel tank while there is still some fuel left in the tank. Protecting the fuel system against freezing and water condensation.
3. Cold areas In snow-covered areas, mountainous areas, skiing areas, etc. Where ambient temperatures drop below 0°C (32°F) throughout the winter season, use an anti-freeze solution in the cooling system. Refueling will also complement the effect of anti-freeze solution each time the fuel level drops to about one-half. After the winter season, drain the water which may have accumulated in the fuel filter and fuel tank in the manner same as that described under Affected areas below.
4. Affected areas When the water condensation is notched in the fuel filter, drain the water from both the fuel filter and fuel tank or use a water removing agent (or anti-freeze solution) in the fuel tank. Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water removing agent) container before use.

See also:
• SELF-DIAGNOSTICS - 2.0L
• SYSTEM & COMPONENT TESTING
• REMOVAL & INSTALLATION - ENGINE PERFORMANCE
• AIR INTAKE SYSTEM
• REMOVAL
• REMOVAL
• RELEASING OF FUEL PRESSURE
• DRAINING FUEL
• REMOVAL
• REMOVAL