Fuel System - SOHC Subaru Impreza WRX GD/GG рестайлинг

GENERAL DESCRIPTION

Note. For information on fuel system testing, see SELF-DIAGNOSTICS - 2.5L 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 the ground cable 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 removal and installation, see AIR INTAKE SYSTEM , Engine Mechanical.

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1. Release the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__releasing-of-fuel-pressure) , FUEL, FUEL SYSTEM SERVICING.
2. Open the fuel flap lid, and remove the fuel filler cap.
3. Disconnect the ground cable from battery.
4. Remove the resonator chamber, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4so) , Resonator Chamber.
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, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mecahnical-25l-sohc) , 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 reservoir 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 connectors from the fuel injectors.
9. Remove the bolts 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, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__releasing-of-fuel-pressure) , FUEL, FUEL SYSTEM SERVICING.
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 connectors from the fuel injectors.
12. Remove the bolts 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.

RH SIDE

Install in the reverse order of removal.

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1. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7 ft-lb)

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1. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)

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1. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)

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1. Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)

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LH SIDE

Install in the reverse order of removal.

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1. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7 ft-lb)

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1. Tightening torque: 5.0 N.m (0.51 kgf-m, 3.7 ft-lb)

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1. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)

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1. Tightening torque: 19 N.m (1.9 kgf-m, 13.7 ft-lb)

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1. Disconnect the ground cable from battery.
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 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 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 fuel pump.
5. Remove the fuel pump relay from the mounting bracket.

Install in the reverse order of removal.

RELEASING OF FUEL PRESSURE

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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 a lift.
2. Disconnect the ground cable from battery.
3. Open the fuel filler flap lid, and then remove the fuel filler cap.
4. Lift up the vehicle.
5. Drain the fuel from the fuel tank. Set a container under the vehicle and remove the drain plugs from the fuel tank.
6. 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 a lift.
2. Release the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__releasing-of-fuel-pressure) , FUEL, FUEL SYSTEM SERVICING.
3. Drain the fuel from the fuel tank. See «DRAINING FUEL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__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 the 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 hoses from the canister.
9. Disconnect the connector from pressure control solenoid valve.
10. Disconnect the connector from 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. See «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc) , Return and Evaporation lines.
13. Disconnect the fuel hoses.
14. Support the fuel tank with a transmission jack, remove the bolts from bands and dismount the fuel tank from the vehicle. WARNING: An assistant is required to perform this work.

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1. Support the fuel tank with a transmission jack and push the fuel tank harness into the access hole with the grommet.
2. Set the fuel tank and temporarily tighten the bolts of fuel tank bands. WARNING: An assistant 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. See «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc) , 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 secure with the 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 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.

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 the connections are tight.

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1. Release the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__releasing-of-fuel-pressure) , FUEL, FUEL SYSTEM SERVICING.
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 plugs from the fuel tank.
9. Tighten the fuel drain plugs. 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 cable to battery.

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1. Move the clamp, 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. See «REMOVAL & INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__removal-installation) , Shut Valve.

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1. Install the shut valve on the fuel filler pipe. See «REMOVAL & INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__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 96)

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

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Note. The fuel pump assembly consists of a fuel pump and a fuel level sensor.

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1. Release the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__releasing-of-fuel-pressure) , FUEL, FUEL SYSTEM SERVICING.
2. Open the fuel filler 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 plugs from the 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 fuel pump.
10. Disconnect the quick connector and then disconnect the fuel delivery hose. See «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc) , 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 gaskets with new ones.

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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)

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

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Note. The fuel level sensor is built in the 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-sohc) , 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.

1. Tightening torque: 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 plugs from the 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 the 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. Release the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__releasing-of-fuel-pressure) , FUEL, FUEL SYSTEM SERVICING.
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)

1. Check the inside of fuel filter for dirt and water sediment.
2. If it is clogged, or if the replacement interval has been reached, replace it.
3. If the water is found in it, shake and expel the water from the inlet port.
4. If fuel hoses are damaged at the connecting portion, replace it with a new one.
5. If clamps are badly damaged, replace with new ones.

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1. Remove the fuel tank, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc) , 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 valves.

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. Release the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__releasing-of-fuel-pressure) , FUEL, FUEL SYSTEM SERVICING.
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 a lift.
2. Release the fuel pressure, see «RELEASING OF FUEL PRESSURE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/fuel-system/#fuel-system-sohc__releasing-of-fuel-pressure) , FUEL, FUEL SYSTEM SERVICING.
3. Open the fuel filler 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 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: Always use a new retainer.

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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 approximately 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.

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 - 2.5L
• SYSTEM & COMPONENT TESTING
• REMOVAL & INSTALLATION - ENGINE PERFORMANCE
• AIR INTAKE SYSTEM
• REMOVAL
• REMOVAL
• REMOVAL
• RELEASING OF FUEL PRESSURE
• DRAINING FUEL
• REMOVAL
• REMOVAL & INSTALLATION