FUEL INJECTION

(FUEL SYTEMS)
 General Description
FUEL INJECTION (FUEL SYSTEMS)

1. General Description
A: SPECIFICATIONS
Capacity 60 2 (15.9 US gal, 13.2 Imp gal)
Fuel tank
Location Under rear seat
Type Impeller
Shutoff discharge pressure 450 — 677 kPa (4.59 — 6.9 kg/cm2, 65.27 — 98.2 psi)
Fuel pump
More than 130 2 (34.3 US gal, 28.6 Imp gal)/h
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type

FU(H4DOTC)-2
 General Description
FUEL INJECTION (FUEL SYSTEMS)

B: COMPONENT
1. INTAKE MANIFOLD

(20)

T6
T2 (17)
(16)
T6

(15) T6

T3
T6

T3
(18)
(14)
T3

T6
(19)

(12) T6

T5
(13) (22)

(10)
(11)
T7 T6
(21)
T7
T1
(10)

(9)
(25)
(25)
(24) T1
(8)

(24)
(7)

(23) (9)

(6) T6
T4
(14)
(5)
(4)
(2) (7)
(3) (8)
T1
(1) (12)
(13)

(3)
(2) T1

(3) (2)

FU-00966

FU(H4DOTC)-3
 General Description
FUEL INJECTION (FUEL SYSTEMS)

(1) Fuel pipe ASSY (13) Insulator (24) Purge hose

(2) Fuel hose (14) Fuel injector pipe (25) Tumble generator valve actuator
(3) Clip (15) Pressure regulator
(4) Purge control solenoid valve (16) Pressure regulator hose Tightening torque: N⋅m (kgf-m, ft-lb)
(5) Vacuum hose (17) Fuel pipe protector RH T1: 4.9 (0.5, 3.6)
(6) Vacuum control hose (18) Blow-by hose stay T2: 6.4 (0.65, 4.7)
(7) Intake manifold gasket (19) Intake manifold T3: 8.25 (0.84, 6.1)
(8) Guide pin (20) Wastegate control solenoid valve T4: 16 (1.6, 11.8)
(9) Tumble generator valve ASSY ASSY T5: 17 (1.73, 12.5)
(10) Tumble generator valve gasket (21) Fuel pipe protector LH T6: 19 (1.94, 13.7)
(11) Accelerator cable bracket (22) Nipple T7: 25 (2.5, 18.1)
(12) Fuel injector (23) Purge valve

FU(H4DOTC)-4
 General Description
FUEL INJECTION (FUEL SYSTEMS)

2. AIR INTAKE SYSTEM

T1 (3)

T2

(5)

(7)
(6)
T3

(1)

(2)

(4)
T1

FU-00002

(1) Gasket (5) Manifold absolute pressure sensor Tightening torque: N⋅m (kgf-m, ft-lb)
(2) Throttle position sensor (6) Gasket T1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve (7) O-ring T2: 2.8 (0.29, 2.1)
(4) Throttle body T3: 22 (2.2, 15.9)

FU(H4DOTC)-5
 General Description
FUEL INJECTION (FUEL SYSTEMS)

3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS

T2
(3)

T1 T1

(1)

(2)

FU-00363

(1) Crankshaft position sensor (3) Camshaft position sensor Tightening torque: N⋅m (kgf-m, ft-lb)
(2) Knock sensor T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)

FU(H4DOTC)-6
 General Description
FUEL INJECTION (FUEL SYSTEMS)

4. FUEL TANK

T1 (12)
(13)

T1 (14)
(17)

(9)
C (11)
B (10)
A (18)
(38) (16)

(15)
(37)
(31) T1
(7) (8) T1 (19)

(6) (6) (11)

(32)
(10)
C (22)
T1 (23)

D B
(34)
T2 (30)
(35) (20)
(13)
(5) (36) (33) A
(21)
(29)

(28) D

(25)

(24)

(2)
(21)
(20)
T3

(26) (13)
T3 (27)

T2
(4)

(2)

(3)
T2

(1) T2
T2
T2
FU-01030

FU(H4DOTC)-7
 General Description
FUEL INJECTION (FUEL SYSTEMS)

(1) Heat shield cover (16) Evaporation hose B (31) Protector cover
(2) Fuel tank band (17) Evaporation hose D (32) Vent valve hose
(3) Protector LH (18) Evaporation hose E (33) Vent valve
(4) Protector RH (19) Evaporation pipe ASSY (34) Fuel tank pressure sensor
(5) Fuel tank (20) Retainer (35) Fuel tank pressure sensor hose
(6) Canister hose A (21) Quick connector (36) Vent valve gasket
(7) Clamp (22) Jet pump hose A (37) Fuel tank sensor control valve
(8) Fuel pump gasket (23) Fuel return hose A (38) Fuel level sensor
(9) Fuel pump ASSY (24) Fuel pipe ASSY
(10) Fuel cut valve gasket (25) Jet pump hose B Tightening torque: N⋅m (kgf-m, ft-lb)
(11) Fuel cut valve (26) Fuel return hose B T1: 4.4 (0.45, 3.3)
(12) Evaporation hose A (27) Evaporation hose F T2: 7.4 (0.75, 5.4)
(13) Clip (28) Fuel sub level sensor gasket T3: 33 (3.4, 25)
(14) Joint pipe (29) Jet pump filter
(15) Evaporation hose C (30) Fuel sub level sensor

FU(H4DOTC)-8
 General Description
FUEL INJECTION (FUEL SYSTEMS)

5. FUEL LINE

(18) (19)
(20)
(17)
(13)
(21)

T2 (22)
(27)
(23)
(28) (25) (26)
(24)

(14)

T2
(29)
(15) T1
(16)
T2

T3
(1)
T3
(1)

(11)
(12)

(10)
(9)
(1) T3

(30)
(8)

(7)
(2)
(6)

(5)
(3)
(4)

FU-01026

FU(H4DOTC)-9
 General Description
FUEL INJECTION (FUEL SYSTEMS)

(1) Clamp (13) Evaporation hose J (25) Canister holder

(2) Fuel delivery hose A (14) Evaporation hose K (26) Evaporation hose L
(3) Fuel filter bracket (15) Joint pipe (27) Pressure control solenoid valve
(4) Fuel filter holder (16) Canister hose A (28) Canister hose B
(5) Fuel filter cup (17) Air filter hose A (29) Canister
(6) Fuel filter (18) Drain valve hose (30) Fuel pipe ASSY
(7) Evaporation hose (19) Air filter hose B
(8) Clip (20) Drain filter Tightening torque: N⋅m (kgf-m, ft-lb)
(9) Fuel delivery hose B (21) Drain valve T1: 25 (2.5, 18.1)
(10) Fuel return hose A (22) Canister upper bracket T2: 23 (2.3, 16.6)
(11) Fuel return hose B (23) Cushion rubber T3: 1.25 (0.13, 0.94)
(12) Fuel damper (24) Canister lower bracket

FU(H4DOTC)-10
 General Description
FUEL INJECTION (FUEL SYSTEMS)

6. FUEL FILLER PIPE

(9)

(8)
(11)
(10)
(1)

(15)
T1
T2

(13) (12)

(3)
T2

(5) T2
(2)

(3)

T2
(14)

(6)

(4)
T2
(7)

FU-00778

(1) Fuel filler pipe ASSY (8) Filler pipe packing (15) Fuel filler pipe protector
(2) Evaporation hose holder (9) Filler ring
(3) Clip (10) Filler cap Tightening torque: N⋅m (kgf-m, ft-lb)
(4) Clamp (11) Shut valve T1: 4.4 (0.45, 3.3)
(5) Evaporation hose A (12) Evaporation hose B T2: 7.5 (0.76, 5.5)
(6) Evaporation pipe (13) Evaporation hose C
(7) Evaporation pipe holder (14) Joint pipe

FU(H4DOTC)-11
 General Description
FUEL INJECTION (FUEL SYSTEMS)

C: CAUTION • Be careful not to burn your hands, because each

• Wear working clothing, including a cap, protec- part on the vehicle is hot after running.
tive goggles, and protective shoes during opera- • Be sure to tighten fasteners including bolts and
tion. nuts to the specified torque.
• Remove contamination including dirt and corro- • Place shop jacks or safety stands at the specified
sion before removal, installation or disassembly. points.
• Keep the disassembled parts in order and pro- • Before disconnecting electrical connectors of
tect them from dust or dirt. sensors or units, be sure to disconnect negative
• Before removal, installation or disassembly, be terminal from battery.
sure to clarify the failure. Avoid unnecessary re- • Place “NO FIRE” signs near the working area.
moval, installation, disassembly, and replacement. • Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA230 CARTRIDGE Troubleshooting for electrical system.

ST24082AA230
22771AA030 SELECT MONI- Troubleshooting for electrical systems.
TOR KIT

ST22771AA030

FU(H4DOTC)-12
 Throttle Body
FUEL INJECTION (FUEL SYSTEMS)

2. Throttle Body 6) Remove the bolts which secure the throttle body
to intake manifold.
A: REMOVAL
1) Disconnect the ground cable from battery.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
22 N⋅m (2.2 kgf-m, 15.9 ft-lb)

FU-00009

2) Remove the intercooler. <Ref. to IN(H4DOTC)-

10, REMOVAL, Intercooler.>
3) Disconnect the connector from the throttle posi-
tion sensor (A) and idle air control solenoid valve
(B) and manifold absolute pressure sensor (C). FU-00013

(B) 2) Adjust the play of accelerator cable. <Ref. to

SP(H4SO)-6, INSTALLATION, Accelerator Control
Cable.>
(C)

(A)

FU-00010

4) Disconnect the accelerator cable.

FU-00011

5) Disconnect the engine coolant hoses from the

throttle body.

FU-00012

FU(H4DOTC)-13
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

3. Intake Manifold 12) Remove the power steering pump.

(1) Remove the front side V-belt. <Ref. to
A: REMOVAL ME(H4DOTC)-42, REMOVAL, V-belt.>
1) Release the fuel pressure. <Ref. to (2) Disconnect the power steering switch con-
FU(H4DOTC)-52, RELEASING OF FUEL PRES- nector.
SURE, PROCEDURE, Fuel.>
2) Open the fuel filler lid and remove the fuel filler
cap.
3) Disconnect the ground cable from battery.

FU-00017

(3) Remove the bolts which secure the power

steering pipe brackets to the intake manifold.
FU-00009 NOTE:
Do not disconnect the power steering hose.
4) Lift up the vehicle.
5) Remove the under cover.
6) Drain the engine coolant about 3.0 2 (3.2 US qt,
2.6 Imp qt).

FU-00018

(4) Remove the bolts which secure the power

steering pump bracket.
FU-00016

7) Remove the air cleaner upper cover and air in-

take boot. <Ref. to IN(H4DOTC)-7, REMOVAL, Air
Cleaner.>
8) Remove the air cleaner element.
9) Remove the intercooler. <Ref. to IN(H4DOTC)-
10, REMOVAL, Intercooler.>
10) Disconnect the accelerator cable.

FU-00019

FU-00011

11) Remove the coolant filler tank. <Ref. to

CO(H4DOTC)-32, REMOVAL, Coolant Filler
Tank.>

FU(H4DOTC)-14
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

(5) Remove the power steering tank from the 15) Disconnect the brake booster hose.
bracket by pulling it upward.

FU-00023
FU-00020
16) Disconnect the pressure hose from the intake
(6) Place the power steering pump on the right duct.
side wheel apron.

FU-00024
FU-00021
17) Disconnect the engine harness connectors
13) Disconnect the emission hose (A) and connec- from the bulkhead harness connectors.
tor (B) from the PCV hose assembly.

(A)
(B)

FU-00025
FU-01032

14) Disconnect the engine coolant hoses from the

throttle body.

FU-00026

FU-00012

FU(H4DOTC)-15
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

18) Disconnect the connectors from the engine 22) Disconnect the engine harness fixed by clip (A)
coolant temperature sensor (A), oil pressure switch from the bracket.
(B) and crankshaft position sensor (C).

(A) (A)
(B)

(C)

FU-00031
FU-00027
23) Disconnect the fuel delivery hose, return hose
19) Disconnect the knock sensor connector. and evaporation hose.
CAUTION:
• Do not spill fuel.
• Catch fuel from hoses in a container or cloth.

FU-00028

20) Disconnect the connector from the camshaft

position sensor.
FU-00032

24) Remove the bolts which secure the intake man-

ifold to the cylinder heads.

FU-00059

21) Disconnect the connector from the ignition coil.

FU-00033

25) Remove the intake manifold.

FU-00030

FU(H4DOTC)-16
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 4) Connect the connector to the knock sensor.

1) Install the intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
Tightening torque:
25 N⋅m (2.5 kgf-m, 18.1 ft-lb)

FU-00028

5) Connect the connector to the camshaft position

sensor.

FU-00033

2) Connect the fuel delivery hose, return hose and

evaporation hose.

FU-00059

6) Connect the connector to the ignition coil.

FU-00032

3) Connect the connector to the oil pressure switch

(B), crankshaft position sensor (C) and engine
coolant temperature sensor (A).

FU-00030
(A)
7) Connect the engine harness with clip (A) to the
(B)
bracket.
(C)

(A)
FU-00027

FU-00031

FU(H4DOTC)-17
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

8) Connect the engine harness connector to the 11) Connect the emission hose (A) and connector
bulkhead harness connectors. (B) to the PCV hose assembly.

(A)
(B)

FU-00025 FU-01032

12) Connect the pressure hose to the intake duct.

FU-00026
FU-00024
9) Connect the brake booster vacuum hose.
13) Install the power steering pump.
(1) Install the power steering tank on the brack-
et.

FU-00023

10) Connect the engine coolant hoses to the throt-

tle body.
FU-00020

(2) Connect the connector to the power steering

pump switch.

FU-00012

FU-00017

FU(H4DOTC)-18
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

(3) Install the power steering pump, and tighten 19) Connect the connector to the fuel pump relay.
the bolts.
Tightening torque:
22 N⋅m (2.2 kgf-m, 15.9 ft-lb)

ME-00649

20) Connect the battery ground cable to battery.

21) Lift up the vehicle.
FU-00019 22) Install the under cover.
23) Fill the engine coolant. <Ref. to CO(H4SO)-12,
(4) Install the power steering pipe brackets on FILLING OF ENGINE COOLANT, REPLACE-
the intake manifold RH. MENT, Engine Coolant.>
C: DISASSEMBLY
1) Remove the fuel pipe protector LH.

FU-00018

(5) Install the front side V-belt. <Ref. to

ME(H4DOTC)-42, REMOVAL, V-belt.>
FU-00968
14) Install the coolant filler tank. <Ref. to
CO(H4DOTC)-32, INSTALLATION, Coolant Filler 2) Remove the fuel pipe protector RH.
Tank.>
15) Connect the accelerator cable.

FU-00035

FU-00011

16) Install the intercooler. <Ref. to IN(H4DOTC)-

10, INSTALLATION, Intercooler.>
17) Install the air cleaner element.
18) Install the air cleaner upper cover and air intake
duct as a unit. <Ref. to IN(H4DOTC)-7, INSTALLA-
TION, Air Cleaner.>

FU(H4DOTC)-19
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

3) Remove the engine ground terminal from the in- 7) Disconnect the connector from the fuel injector.
take manifold.

FU-00615
FU-00036
8) Disconnect the connector from the tumble gen-
erator valve actuator.

FU-00037
FU-00616
4) Disconnect the connector from the throttle posi-
tion sensor (A), idle air control solenoid valve (B) 9) Disconnect the connector from the tumble gen-
and manifold absolute pressure sensor (C). erator valve sensor.
5) Disconnect the engine harness fixed by clip (D)
from the intake manifold.

(C) (A)
(B)

FU-00617

(D) (D) 10) Disconnect the connector from the purge con-
FU-00038
trol solenoid valve.
6) Remove the throttle body from the intake mani-
fold.

FU-00040

FU-00013

FU(H4DOTC)-20
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

11) Remove the purge control solenoid valve. • LH SIDE

FU-00041 FU-00044

12) Disconnect the evaporation hose from the in-

take manifold.

FU-00618

• RH SIDE
FU-00042

13) Disconnect the evaporation hoses from the

purge valve.

FU-00046

FU-00364

14) Remove the two bolts which hold the fuel pipes
on the left side of intake manifold.

FU-00619

FU-00043

15) Remove the bolt which hold the fuel injector

pipe onto intake manifold.

FU(H4DOTC)-21
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

16) Remove the fuel injector. 22) Remove the fuel pipe assembly and pressure
regulator, from the intake manifold.
23) Remove the intake duct from the intake mani-
fold.

FU-00048

17) Remove the harness bracket which holds the

engine harness onto intake manifold. FU-00052

24) Remove the tumble generator valve assembly

from the intake manifold.

FU-00049

18) Remove the engine harness from the intake

manifold. FU-00053
19) Loosen the clamp which holds the front left side
fuel hose to injector pipe and remove the pipe from D: ASSEMBLY
clamp.
NOTE:
Replace the gasket with a new one.
1) Install the tumble generator valve assembly to
the intake manifold.
Tightening torque:
8.25 N⋅m (0.84 kgf-m, 6.1 ft-lb)

FU-00620

20) Remove the fuel injector pipe LH.

21) Remove the bolts which install the fuel pipe on
intake manifold.

FU-00053

FU-00051

FU(H4DOTC)-22
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

2) Install the air intake duct to the intake manifold. Tightening torque:
Tightening torque: 19 N⋅m (1.94 kgf-m, 13.7 ft-lb)
19 N⋅m (1.94 kgf-m, 13.7 ft-lb)

FU-00049

FU-00052 8) Install the fuel injector.

3) Install the fuel pipe assembly and pressure reg-
ulator to the intake manifold.
Tightening torque:
4.9 N⋅m (0.5 kgf-m, 3.6 ft-lb)

FU-00048

9) Tighten the bolts which install the fuel injector

pipe onto intake manifold.
Tightening torque:
FU-00051 19 N⋅m (1.94 kgf-m, 13.7 ft-lb)
• LH SIDE
4) Install the fuel injector pipe LH.
5) Connect the left side fuel hose to injector pipe,
and tighten the clamp screw.

FU-00044

FU-00620

6) Install the engine harness to the intake manifold.

7) Install the harness bracket which holds the en-
gine harness onto intake manifold.

FU-00618

FU(H4DOTC)-23
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

• RH SIDE NOTE:
Connect the evaporation hoses as shown in the fig-
ure.

(B)

(A)

FU-00046

(C)

(D)

FU-00619

10) Tighten the two bolts which install the fuel pipes
on the left side of intake manifold. FU-00365

Tightening torque:
(A) To fuel pipe ASSY
4.9 N⋅m (0.5 kgf-m, 3.6 ft-lb)
(B) To intake duct
(C) To purge control solenoid valve
(D) To intake manifold

12) Connect the evaporation hose to the intake

manifold.

FU-00043

11) Connect the evaporation hoses to the purge

valve.

FU-00042

FU(H4DOTC)-24
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

13) Install the purge control solenoid valve. 16) Connect the connector to the tumble generator
valve sensor.
Tightening torque:
16 N⋅m (1.6 kgf-m, 11.8 ft-lb)

FU-00617

FU-00041 17) Connect the connector to the tumble generator

valve actuator.
14) Connect the hoses to the purge control sole-
noid valve.
NOTE:
Connect the evaporation hoses as shown in the fig-
ure.

FU-00616

18) Connect the connector to the fuel injector.

(A)

(B)
FU-00054

(A) To intake manifold

(B) To purge valve

15) Connect the connector to the purge control so-

lenoid valve.
FU-00615

19) Install the throttle body to the intake manifold.

NOTE:
Replace the gasket with a new one.
Tightening torque:
22 N⋅m (2.2 kgf-m, 15.9 ft-lb)

FU-00040

FU-00013

FU(H4DOTC)-25
 Intake Manifold
FUEL INJECTION (FUEL SYSTEMS)

20) Connect the connector to the throttle position 23) Install the fuel pipe protector RH.
sensor (A), idle air control solenoid valve (B) and
Tightening torque:
manifold absolute pressure sensor (C).
19 N⋅m (1.94 kgf-m, 13.7 ft-lb)
21) Connect the engine harness to the intake man-
ifold using clips (D).

(C) (A)
(B)

FU-00969
(D) (D)
FU-00038 24) Install the fuel pipe protector LH.
22) Install the engine ground terminal to the intake Tightening torque:
manifold. 19 N⋅m (1.94 kgf-m, 13.7 ft-lb)
Tightening torque:
19 N⋅m (1.94 kgf-m, 13.7 ft-lb)

FU-00968

FU-00036
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
cracked and the connections are tightened.

FU-00037

FU(H4DOTC)-26
 Engine Coolant Temperature Sensor
FUEL INJECTION (FUEL SYSTEMS)

4. Engine Coolant Temperature

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

FU-00009

2) Remove the generator. <Ref. to SC(H4SO)-14,

REMOVAL, Generator.>
3) Drain the engine coolant. <Ref. to
CO(H4DOTC)-17, DRAINING OF ENGINE COOL-
ANT, REPLACEMENT, Engine Coolant.>
4) Disconnect the connector from the engine cool-
ant temperature sensor.

FU-00055

5) Remove the engine coolant temperature sensor.

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
18 N⋅m (1.8 kgf-m, 13.3 ft-lb)

FU(H4DOTC)-27
 Crankshaft Position Sensor
FUEL INJECTION (FUEL SYSTEMS)

5. Crankshaft Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground cable from battery. Tightening torque:
T: 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb)

FU-00009
FU-00058
2) Remove the bolt which installs the crankshaft
position sensor to cylinder block.

FU-00056

3) Remove the crankshaft position sensor, and dis-

connect the connector from it.

FU-00057

FU(H4DOTC)-28
 Camshaft Position Sensor
FUEL INJECTION (FUEL SYSTEMS)

6. Camshaft Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground cable from battery. Tightening torque:
T: 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb)

FU-00009
FU-00060
2) Disconnect the connector from the camshaft po-
sition sensor.

FU-00059

3) Remove the camshaft position sensor from the

camshaft support LH.

FU-00060

FU(H4DOTC)-29
 Knock Sensor
FUEL INJECTION (FUEL SYSTEMS)

7. Knock Sensor B: INSTALLATION

1) Install the knock sensor to the cylinder block.
A: REMOVAL
1) Disconnect the ground cable from battery. Tightening torque:
24 N⋅m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
Extraction area of the knock sensor cord must be
positioned at a 60° angle relative to the engine rear.

(A)

FU-00009

2) Remove the intercooler. <Ref. to IN(H4DOTC)-

10, REMOVAL, Intercooler.> 60
3) Disconnect the knock sensor connector.
FU-00413

(A) Front side

2) Connect the knock sensor connector.

FU-00062

4) Remove the knock sensor from the cylinder

block.

FU-00062

3) Install the intercooler. <Ref. to IN(H4DOTC)-10,

INSTALLATION, Intercooler.>
4) Connect the battery ground cable to battery.

FU-00519

FU-00009

FU(H4DOTC)-30
 Throttle Position Sensor
FUEL INJECTION (FUEL SYSTEMS)

8. Throttle Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground cable from battery. Tightening torque:
1.6 N⋅m (0.16 kgf-m, 1.2 ft-lb)

FU-00009
FU-00066
2) Remove the intercooler. <Ref. to IN(H4DOTC)-
10, REMOVAL, Intercooler.>
3) Disconnect the connector from the throttle posi-
tion sensor.

FU-00065

4) Remove the throttle position sensor holding

screws, and remove the throttle position sensor.

FU-00066

FU(H4DOTC)-31
 Mass Air Flow and Intake Air Temperature Sensor
FUEL INJECTION (FUEL SYSTEMS)

9. Mass Air Flow and Intake Air

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

FU-00009

2) Disconnect the connector from mass air flow and

intake air temperature sensor.
3) Remove the mass air flow and intake air temper-
ature sensor.

FU-00067

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
1.7 N⋅m (0.17 kgf-m, 1.3 ft-lb)

FU(H4DOTC)-32
 Manifold Absolute Pressure Sensor
FUEL INJECTION (FUEL SYSTEMS)

10.Manifold Absolute Pressure

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

FU-00009

2) Remove the idle air control solenoid valve. <Ref.

to FU(H4DOTC)-34, REMOVAL, Idle Air Control
Solenoid Valve.>
3) Disconnect the connectors from manifold abso-
lute pressure sensor.

FU-00068

4) Remove the manifold absolute pressure sensor

from the throttle body.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Replace the O-rings for the manifold absolute pres-
sure sensor with new ones.
Tightening torque:
1.6 N⋅m (0.16 kgf-m, 1.2 ft-lb)

FU(H4DOTC)-33
 Idle Air Control Solenoid Valve
FUEL INJECTION (FUEL SYSTEMS)

11.Idle Air Control Solenoid B: INSTALLATION

Valve Install in the reverse order of removal.
NOTE:
A: REMOVAL Replace the gasket with a new one.
1) Disconnect the ground cable from battery.
Tightening torque:
2.8 N⋅m (0.29 kgf-m, 2.1 ft-lb)

FU-00009

2) Disconnect the connector from the idle air con-

FU-00071
trol solenoid valve.

FU-00070

3) Remove the idle air control solenoid valve from

the throttle body.

FU-00071

4) Remove the gasket from the throttle body.

FU-00072

FU(H4DOTC)-34
 Fuel Injector
FUEL INJECTION (FUEL SYSTEMS)

12.Fuel Injector 7) Remove the bolts which hold the injector pipe to
intake manifold.
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the ground cable from battery.
FU-00046

FU-00009

4) Remove the intake manifold. <Ref. to

FU(H4DOTC)-14, REMOVAL, Intake Manifold.> FU-00619

5) Remove the fuel pipe protector RH. 8) Remove the fuel injector while lifting up the fuel
injector pipe.

FU-00035

6) Disconnect the connector from the fuel injector. FU-00048

2. LH SIDE
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the ground cable from battery.

FU-00615

FU-00009

FU(H4DOTC)-35
 Fuel Injector
FUEL INJECTION (FUEL SYSTEMS)

4) Remove the intake manifold. <Ref. to 7) Remove the bolts which hold the injector pipe to
FU(H4DOTC)-14, REMOVAL, Intake Manifold.> intake manifold.
5) Remove the fuel pipe protector LH.

FU-00043
FU-00968

6) Disconnect the connector from the fuel injector.

FU-00618

FU-00615

FU-00044

8) Remove the fuel injector while lifting up the fuel

injector pipe.

FU-00048

FU(H4DOTC)-36
 Fuel Injector
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION Tightening torque:

19 N⋅m (1.94 kgf-m, 13.7 ft-lb)
1. RH SIDE
Install in the reverse order of removal.
NOTE:
Replace the O-ring and insulators with new ones.

(A) FU-00035
(C)
(B) 2. LH SIDE
(C)
Install in the reverse order of removal.
FU-00073 NOTE:
Replace the O-ring and insulators with new ones.
(A) O-ring
(B) Fuel injector
(C) Insulator

Tightening torque:
19 N⋅m (1.94 kgf-m, 13.7 ft-lb) (A)
(C)
(B)
(C)

FU-00073

(A) O-ring
(B) Fuel injector
(C) Insulator

FU-00046 Tightening torque:

4.9 N⋅m (0.5 kgf-m, 3.6 ft-lb)
Tightening torque:
19 N⋅m (1.94 kgf-m, 13.7 ft-lb)

FU-00043

FU-00619

FU(H4DOTC)-37
 Fuel Injector
FUEL INJECTION (FUEL SYSTEMS)

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

FU-00044

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

FU-00618

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

FU-00968

FU(H4DOTC)-38
 Tumble Generator Valve Assembly
FUEL INJECTION (FUEL SYSTEMS)

13.Tumble Generator Valve As- 8) Remove the tumble generator valve body from
the intake manifold.
sembly
A: REMOVAL
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
2) Open the fuel filler lid and remove the fuel filler
cap.
3) Disconnect the ground cable from battery.

FU-00053

B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Always use new gaskets.
Tightening torque:
8.25 N⋅m (0.84 kgf-m, 6.1 ft-lb)
FU-00009

4) Remove the intake manifold. <Ref. to

FU(H4DOTC)-14, REMOVAL, Intake Manifold.>
5) Disconnect the connector from the tumble gen-
erator valve sensor.

FU-00053

FU-00617

6) Disconnect the connector from the tumble gen-

erator valve actuator.

FU-00616

7) Remove the fuel injector. <Ref. to

FU(H4DOTC)-35, REMOVAL, Fuel Injector.>

FU(H4DOTC)-39
 Tumble Generator Valve Position Sensor
FUEL INJECTION (FUEL SYSTEMS)

14.Tumble Generator Valve Po-

sition Sensor
A: SPECIFICATION
Do not remove the tumble generator valve position
sensor from tumble generator valve assembly,
since it cannot be adjusted during installation.
Refer to “Tumble Generator Valve Assembly” for
removal and installation procedures. <Ref. to
FU(H4DOTC)-39, REMOVAL, Tumble Generator
Valve Assembly.> <Ref. to FU(H4DOTC)-39, IN-
STALLATION, Tumble Generator Valve Assem-
bly.>

FU(H4DOTC)-40
 Tumble Generator Valve Actuator
FUEL INJECTION (FUEL SYSTEMS)

15.Tumble Generator Valve Ac- 3) Disconnect the ground cable from battery.
tuator
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
2) Open the fuel filler lid and remove the fuel filler
cap. FU-00009
3) Disconnect the ground cable from battery.
4) Disconnect the connector from tumble generator
valve LH.
5) Remove the tumble generator valve actuator LH.

FU-00009

4) Remove the intake manifold. <Ref. to

FU(H4DOTC)-14, REMOVAL, Intake Manifold.> FU-00622
5) Disconnect the connector from tumble generator
valve actuator RH. B: INSTALLATION
6) Remove the tumble generator valve RH.
1. RH SIDE
Install in the reverse order of removal.
2. LH SIDE
Install in the reverse order of removal.

FU-00621

2. LH SIDE
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
2) Open the fuel filler lid and remove the fuel filler
cap.

FU(H4DOTC)-41
 Wastegate Control Solenoid Valve
FUEL INJECTION (FUEL SYSTEMS)

16.Wastegate Control Solenoid 6) Remove the wastegate control solenoid valve

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

FU-00368

B: INSTALLATION
Install in the reverse order of removal.
FU-00009
Tightening torque:
2) Disconnect the engine harness connector (A) 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb)
from bracket.
3) Disconnect the connector (B) from wastegate
control solenoid valve.
4) Remove the bracket from body.

(B)

(A) FU-00368

FU-00366

5) Disconnect the pressure hoses (C) from waste-

gate control solenoid valve.

(C)

FU-00367

FU(H4DOTC)-42
 Front Oxygen (A/F) Sensor
FUEL INJECTION (FUEL SYSTEMS)

17.Front Oxygen (A/F) Sensor 7) Apply SUBARU CRC or its equivalent to the
threaded portion of front oxygen (A/F) sensor, and
A: REMOVAL leave it for one minute or more.
1) Disconnect the ground cable from battery.
SUBARU CRC (Part No. 004301003)
8) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the oxygen (A/F) sensor, wait
until exhaust pipe cools, otherwise it will dam-
age exhaust pipe.

FU-00009

2) Disconnect the connector from the front oxygen

(A/F) sensor.

FU-00080

B: INSTALLATION
1) Before installing front oxygen (A/F) sensor, ap-
ply anti-seize compound only to the threaded por-
tion of front oxygen (A/F) sensor to make the next
removal easier.
FU-00369 Anti-seize compound:
3) Disconnect the engine harness fixed by clip (A) SS-30 by JET LUBE
from the bracket (B). CAUTION:
Never apply anti-seize compound to protector
of front oxygen (A/F) sensor.
2) Install the front oxygen (A/F) sensor.
Tightening torque:
30 N⋅m (3.1 kgf-m, 22.1 ft-lb)
(B)

(A)
FU-00078

4) Remove the front right side wheel.

5) Lift-up the vehicle.
6) Remove the service hole cover.

FU-00080

FU-00783

FU(H4DOTC)-43
 Front Oxygen (A/F) Sensor
FUEL INJECTION (FUEL SYSTEMS)

3) Install the service hole cover.

FU-00783

4) Lower the vehicle.

5) Install the front right side wheel.
6) Connect the engine harness to the bracket (B)
using clips (A).

(B)

(A)
FU-00078

7) Connect the connector of front oxygen (A/F)

sensor.

FU-00369

8) Connect the battery ground cable to battery.

FU-00009

FU(H4DOTC)-44
 Rear Oxygen Sensor
FUEL INJECTION (FUEL SYSTEMS)

18.Rear Oxygen Sensor CAUTION:

When removing the oxygen sensor, wait until
A: REMOVAL exhaust pipe cools, otherwise it will damage ex-
1) Disconnect the ground cable from battery. haust pipe.

FU-00009
FU-00371
2) Lift-up the vehicle.
3) Disconnect the connector from the rear oxygen B: INSTALLATION
sensor. 1) Before installing rear oxygen sensor, apply anti-
seize compound only to the threaded portion of
rear oxygen sensor to make the next removal eas-
ier.
CAUTION:
Never apply anti-seize compound to protector
of rear oxygen sensor.
Anti-seize compound:
SS-30 by JET LUBE
2) Install the rear oxygen sensor.
FU-00081
Tightening torque:
4) Remove the clip by pulling out from the upper 21 N⋅m (2.1 kgf-m, 15.2 ft-lb)
side of crossmember.

FU-00371
FU-00082
3) Connect the connector to the rear oxygen sen-
5) Apply SUBARU CRC or its equivalent to the sor.
threaded portion of rear oxygen sensor, and leave
it for one minute or more.
SUBARU CRC (Part No. 004301003)
6) Remove the rear oxygen sensor.

FU-00081

FU(H4DOTC)-45
 Rear Oxygen Sensor
FUEL INJECTION (FUEL SYSTEMS)

4) Connect the clip to the crossmember.

FU-00082

5) Lower the vehicle.

6) Connect the battery ground cable to battery.

FU-00009

FU(H4DOTC)-46
 Exhaust Temperature Sensor
FUEL INJECTION (FUEL SYSTEMS)

19.Exhaust Temperature Sensor Tightening torque:

21 N⋅m (2.1 kgf-m, 15.2 ft-lb)
A: REMOVAL
1) Disconnect the ground cable from battery. (A)

(B)

FU-01018

FU-00009
3) Install the joint pipe. <Ref. to EX(H4DOTC)-12,
INSTALLATION, Joint Pipe.>
2) Remove the joint pipe. <Ref. to EX(H4DOTC)- 4) Connect the battery ground cable to battery.
12, REMOVAL, Joint Pipe.>
3) Apply SUBARU CRC or its equivalent to the
threaded portion of exhaust temperature sensor,
and leave it for one minute or more.
SUBARU CRC (Part No. 004301003)
4) Remove the exhaust temperature sensor.
CAUTION:
When removing the oxygen sensor, wait until
exhaust pipe cools, otherwise it will damage ex-
haust pipe. FU-00009

FU-00372

B: INSTALLATION
1) Before installing exhaust temperature sensor,
apply anti-seize compound only to the threaded
portion of rear oxygen sensor to make the next re-
moval easier.
CAUTION:
Never apply anti-seize compound to protector
of exhaust temperature sensor.
Anti-seize compound:
SS-30 by JET LUBE
2) Install the exhaust temperature sensor.
NOTE:
Align the harness (A) of exhaust temperature sen-
sor to the marking (B) of joint pipe, and tighten the
screws.

FU(H4DOTC)-47
 Engine Control Module (ECM)
FUEL INJECTION (FUEL SYSTEMS)

20.Engine Control Module (ECM)

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

FU-00009

2) Remove the lower inner trim of the passenger

side. <Ref. to EI-49, REMOVAL, Lower Inner
Trim.>
3) Detach the floor mat of the front passenger seat.
4) Remove the protect cover.

FU-01029

5) Remove the nuts (A) which hold ECM to the

bracket.
6) Remove the clip (B) from the bracket.

(A)

(A)
(B)

FU-00316

7) Disconnect the ECM connectors and take out

the ECM.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
When replacing ECM, be careful not to use the
wrong spec. ECM to avoid any damage to the fuel
injection system.

FU(H4DOTC)-48
 Main Relay
FUEL INJECTION (FUEL SYSTEMS)

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

FU-00009

2) Remove the passenger’s side front side sill cov-

er.
3) Remove the bolt which holds the main relay
bracket on the body.
4) Disconnect the connectors from the main relay.

FU-00785

B: INSTALLATION
Install in the reverse order of removal.

FU(H4DOTC)-49
 Fuel Pump Relay
FUEL INJECTION (FUEL SYSTEMS)

22.Fuel Pump Relay

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

FU-00009

2) Remove the passenger’s side front side sill cov-

er.
3) Remove the bolt which holds fuel pump relay
bracket on the body.
4) Disconnect the connector from the fuel pump re-
lay.

ME-00649

5) Remove the fuel pump relay from the mounting

bracket.
B: INSTALLATION
Install in the reverse order of removal.

FU(H4DOTC)-50
 Fuel Pump Control Unit
FUEL INJECTION (FUEL SYSTEMS)

23.Fuel Pump Control Unit

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

FU-00009

2) Remove the rear quarter trim. <Ref. to EI-50,

REMOVAL, Rear Quarter Trim.>
3) Disconnect the connector from the fuel pump
control unit.

FU-00087

4) Remove the fuel pump control unit.

FU-00088

B: INSTALLATION
Install in the reverse order of removal.

FU(H4DOTC)-51
 Fuel
FUEL INJECTION (FUEL SYSTEMS)

24.Fuel 5) Drain the fuel from the fuel tank.

Set a container under the vehicle and remove drain
A: PROCEDURE plug from the fuel tank.
1. RELEASING OF FUEL PRESSURE
WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill the fuel.
1) Disconnect the connector from the fuel pump re-
lay.

FU-00089

6) Tighten the fuel drain plug.

Tightening torque:
26 N⋅m (2.65 kgf-m, 19.2 ft-lb)

ME-00649

2) Start and run the engine until it stalls.

3) After the engine stalls, crank it for five more sec-
onds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING: FU-00089
• Place “NO FIRE” signs near the working area.
• Be careful not to spill the fuel.
1) Set the vehicle on the lift.
2) Disconnect the ground cable from battery.

FU-00009

3) Open the fuel filler flap lid and remove the fuel
filler cap.
4) Lift-up the vehicle.

FU(H4DOTC)-52
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

25.Fuel Tank 10) Disconnect the connector from the drain valve.

A: REMOVAL
WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill the fuel.
1) Set the vehicle on the lift.
2) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
3) Drain the fuel from the fuel tank. <Ref. to FU-00322
FU(H4DOTC)-52, DRAINING FUEL, PROCE-
DURE, Fuel.> 11) Loosen the clamp and disconnect the fuel filler
4) Remove the rear seat. hose (A) from fuel filler pipe.
5) Disconnect the connector (A) of fuel tank cord to 12) Move the clip, and disconnect the evaporation
the rear harness. hose (B).
6) Push the grommet (B) which holds the fuel tank (B)
cord on floor panel into under the body.

(B)

(A)
FU-00327

13) Move the clips, and disconnect the quick con-

(A)
FU-00090 nector. <Ref. to FU(H4DOTC)-69, REMOVAL, Fuel
Delivery, Return and Evaporation Lines.>
7) Remove the rear crossmember. <Ref. to RS-18,
14) Disconnect the fuel hoses.
REMOVAL, Rear Crossmember.>
8) Move the clamp, and disconnect the evaporation
hose from canister.

FU-00093

15) Support the fuel tank with transmission jack, re-

FU-00321 move the bolts from bands and dismount the fuel
tank from vehicle.
9) Disconnect the connector from the pressure
control solenoid valve.

FU(H4DOTC)-53
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

WARNING: 4) Connect the fuel hoses, and hold them with clips
A helper is required to perform this work. and quick connector. <Ref. to FU(H4DOTC)-70,
INSTALLATION, Fuel Delivery, Return and Evapo-
ration Lines.>

FU-00411

B: INSTALLATION FU-00093
1) Support the fuel tank with transmission jack and 5) Connect the connector to the drain valve.
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.

FU-00322

6) Connect the connector to the pressure control

solenoid valve.
7) Connect the evaporation hose to the canister,
and hold them with clamp.

FU-00411

3) Insert the fuel filler hose (A) approx. 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.

(B) FU-00321

(A)
FU-00327

FU(H4DOTC)-54
 Fuel Tank
FUEL INJECTION (FUEL SYSTEMS)

8) Tighten the band mounting bolts.

Tightening torque:
33 N⋅m (3.4 kgf-m, 25 ft-lb)

FU-00411

9) Install the rear crossmember. <Ref. to RS-18,

INSTALLATION, Rear Crossmember.>
10) Connect the connector (A) to the fuel tank cord
and plug the service hole with grommet (B).

(B)

(A)
FU-00090

11) Set the rear seat and floor mat.

12) Connect the connector to the fuel pump relay.

ME-00649

C: 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 tightened firm-
ly.

FU(H4DOTC)-55
 Fuel Filler Pipe
FUEL INJECTION (FUEL SYSTEMS)

26.Fuel Filler Pipe 9) Drain the fuel from fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
A: REMOVAL tank.
WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill the fuel.
1) Set the vehicle on the lift.
2) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
3) Open the fuel filler flap lid and remove the filler
cap.
4) Disconnect the ground cable from battery. FU-00089

10) Tighten the fuel drain plug and then install the
front right side tank cover.
Tightening torque:
26 N⋅m (2.65 kgf-m, 19.2 ft-lb)

FU-00009

5) Remove the screws holding packing.

FU-00089

11) Remove the fuel filler pipe protector.

FU-00095

6) Loosen the rear right side wheel nuts.

7) Lift-up the vehicle.
8) Remove the rear right side wheel.

FU-00786

12) Separate the evaporation hoses from the clip of

fuel filler pipe.

FU-00096

FU-00098

FU(H4DOTC)-56
 Fuel Filler Pipe
FUEL INJECTION (FUEL SYSTEMS)

13) Disconnect the evaporation hoses from the B: INSTALLATION

pipes. 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.
(A)

(B)
FU-00325
(C)
14) Remove the bolts which hold fuel filler pipe
bracket on the body.
FU-00103

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 in-
side, straighten it with a screwdriver.

(A)

FU-00326

15) Loosen the clamp, and disconnect the fuel filler

hose (A) from fuel filler pipe. (B)
16) Move the clip, and disconnect the evaporation
hose (B). (C)

(B)
FU-00103

4) Install the evaporation pipes.

(A)
FU-00327

17) Remove the fuel filler pipe to under side of the

vehicle.
18) Remove the air vent pipe together with clip FU-00328
from the body.

FU-00328

FU(H4DOTC)-57
 Fuel Filler Pipe
FUEL INJECTION (FUEL SYSTEMS)

5) Connect the evaporation hose to pipes. Tightening torque:

7.4 N⋅m (0.75 kgf-m, 5.4 ft-lb)

FU-00325

6) Insert the fuel filler hose (A) approx. 35 to 40 mm FU-00326

(1.38 to 1.57 in) over the lower end of fuel filler pipe 9) Tighten the bolts which hold evaporation hoses
and tighten the clamp. onto the clip of fuel filler pipe.
CAUTION:
Do not allow clips to touch air vent hose (B) and
rear suspension crossmember.

(B)

FU-00098

10) Install the fuel filler pipe protector.

(A)
FU-00327

7) Insert the air vent hose approx. 25 to 30 mm

(0.98 to 1.18 in) into the lower end of air vent pipe,
and hold the clip.
L = 27.5±2.5 mm (1.083±0.098 in)

(2) (3)
(1)

FU-00786

11) Install the rear right wheel.

L/2

L
FU-00104

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

8) Tighten the bolt which holds fuel filler pipe brack- FU-00096

et on the body. 12) Lower the vehicle.

13) Tighten the wheel nuts.

FU(H4DOTC)-58
 Fuel Filler Pipe
FUEL INJECTION (FUEL SYSTEMS)

14) Connect the connector to the fuel pump relay. 3) Disconnect the evaporation hose from the fuel
filler pipe.

ME-00649
FU-00331
15) Connect the battery ground cable to battery.
4) Remove the shut valve from the fuel filler pipe.
<Ref. to EC(H4DOTC)-18, REMOVAL, Shut
Valve.>
D: ASSEMBLY
1) Install the shut valve on the fuel filler pipe. <Ref.
to EC(H4DOTC)-18, INSTALLATION, Shut
Valve.>
2) Connect the evaporation hose to the fuel filler
pipe.
FU-00009

C: DISASSEMBLY
1) Move the clip, and disconnect the evaporation
hose from joint pipe.

FU-00331

3) Connect the evaporation hose to the evapora-

tion pipe.

FU-00329

2) Remove the bolt which installs the joint pipe on

fuel filler pipe.

FU-00329

FU-00330

FU(H4DOTC)-59
 Fuel Filler Pipe
FUEL INJECTION (FUEL SYSTEMS)

4) Install the evaporation pipe to the fuel filler pipe.

FU-00330

FU(H4DOTC)-60
 Fuel Pump
FUEL INJECTION (FUEL SYSTEMS)

27.Fuel Pump Tightening torque:

26 N⋅m (2.65 kgf-m, 19.2 ft-lb)
A: REMOVAL
WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill the fuel.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.> FU-00089
2) Open the fuel filler flap lid and remove the fuel
filler cap. 7) Raise the rear seat and turn the floor mat up.
3) Disconnect the ground cable from battery. 8) Remove the access hole lid.

FU-00105
FU-00009

4) Lift-up the vehicle. 9) Disconnect the connector from the fuel pump.
5) Drain the fuel from fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
tank.

FU-00106

10) Disconnect the quick connector and then dis-

connect the fuel delivery hose (A). <Ref. to
FU-00089 FU(H4DOTC)-69, Fuel Delivery, Return and Evap-
6) Tighten the fuel drain plug. oration Lines.>
11) Move the clips, and then disconnect the fuel re-
turn hose (A) and jet pump hose (B).

(A)

(B)
FU-00320

FU(H4DOTC)-61
 Fuel Pump
FUEL INJECTION (FUEL SYSTEMS)

12) Remove the nuts which install the fuel pump • Do not run fuel pump for a long time under
assembly onto fuel tank. non-load condition.

3 2 1
6 5 4

FU-00108 FU-00375
13) Take off the fuel pump assembly from the fuel
tank.
B: INSTALLATION
Carefully following the steps below, install in the re-
verse order of removal.
NOTE:
Always use new gaskets.
(1) Ensure the sealing portion is free from fuel or
foreign particles before installation.
(2) Tighten the nuts to the specified torque in al-
phabetical sequence as shown in the figure.
Tightening torque:
4.4 N⋅m (0.45 kgf-m, 3.3 ft-lb)

(A) (E)
(C)

(H) (G)

(D)
(F) (B)

FU-00109

C: INSPECTION
Connect the lead harness to the connector terminal
of fuel pump and apply battery power supply to
check whether the pump operate.
WARNING:
• Wipe off the fuel completely.
• Keep battery as far apart from fuel pump as
possible.
• Be sure to turn the battery supply ON and
OFF on the battery side.

FU(H4DOTC)-62
 Fuel Level Sensor
FUEL INJECTION (FUEL SYSTEMS)

28.Fuel Level Sensor

A: REMOVAL
WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill the fuel.
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(H4DOTC)-61, REMOVAL, Fuel Pump.>
2) Disconnect the connector from the fuel pump
bracket.

FU-00111

3) Remove the bolt which installs the fuel level sen-

sor on mounting bracket.

FU-00333

B: INSTALLATION
Install in the reverse order of removal.

FU(H4DOTC)-63
 Fuel Sub Level Sensor
FUEL INJECTION (FUEL SYSTEMS)

29.Fuel Sub Level Sensor 6) Remove the service hole cover.

A: REMOVAL
WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill the fuel.
1) Disconnect the ground cable from battery.

FU-00113

7) Disconnect the connector from the fuel sub level

sensor.
8) Disconnect the fuel jet pump hose.

FU-00009

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
fuel tank.

FU-00114

9) Remove the bolts which install the fuel sub level

sensor on fuel tank.

FU-00089

4) Tighten the fuel drain plug.

Tightening torque:
26 N⋅m (2.65 kgf-m, 19.2 ft-lb)
FU-00115

10) Remove the fuel sub level sensor.

FU-00089

5) Remove the rear seat.

FU-00116

FU(H4DOTC)-64
 Fuel Sub Level Sensor
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N⋅m (0.45 kgf-m, 3.3 ft-lb)

FU-00115

FU(H4DOTC)-65
 Fuel Filter
FUEL INJECTION (FUEL SYSTEMS)

30.Fuel Filter
A: REMOVAL
WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill the fuel.
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
2) Disconnect the fuel delivery hoses from the fuel
filter.

FU-00118

3) Remove the filter from the holder.

B: INSTALLATION
CAUTION:
• If fuel hoses are damaged at the connecting
portion, replace them with new ones.
• If clamps are badly damaged, replace them
with new ones.
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)

FU-00118

C: INSPECTION
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.

FU(H4DOTC)-66
 Fuel Cut Valve
FUEL INJECTION (FUEL SYSTEMS)

31.Fuel Cut Valve

A: REMOVAL
1) Remove the fuel tank. <Ref. to FU(H4DOTC)-
53, REMOVAL, Fuel Tank.>
2) Remove the protect cover.

FU-00334

3) Move the clip and disconnect the evaporation

hose from fuel cut valve.

FU-00410

4) Remove the bolts which install the fuel cut valve.

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N⋅m (0.45 kgf-m, 3.3 ft-lb)

FU-00412

FU(H4DOTC)-67
 Fuel Damper Valve
FUEL INJECTION (FUEL SYSTEMS)

32.Fuel Damper Valve

A: REMOVAL
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-52, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
2) Remove the fuel damper valve from the fuel re-
turn line.

FU-00121

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
1.25 N⋅m (0.13 kgf-m, 0.94 ft-lb)

FU(H4DOTC)-68
 Fuel Delivery, Return and Evaporation Lines
FUEL INJECTION (FUEL SYSTEMS)

33.Fuel Delivery, Return and Evaporation Lines

A: REMOVAL
1) Set the vehicle on a lift.
2) Release the fuel pressure. <Ref. to FU(H4DOTC)-52, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
3) Open the fuel filler flap lid and remove the fuel filler cap.
4) Remove the floor mat. <Ref. to EI-57, REMOVAL, Floor Mat.>
5) Remove the fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses.

FU-00337

FU(H4DOTC)-69
 Fuel Delivery, Return and Evaporation Lines
FUEL INJECTION (FUEL SYSTEMS)

6) In engine compartment, detach the fuel delivery B: INSTALLATION

hose (A), return hose (B) and evaporation hose (C). 1) Connect the quick connector on the fuel delivery
line.
(A)
NOTE:
(B) • Always use a new retainer.
• Make sure that the connected portion is not dam-
aged or has dust. If necessary, clean seal surface
of pipe.

(C) FU-00259 (A)

7) Lift-up the vehicle.

8) Separate the quick connector on the fuel deliv- (B)
ery line.
(1) Clean the pipe and connector, if they are
covered with dust.
(2) Hold the connector (A) and push retainer (B) FU-00125
down.
(3) Pull out the connector (A) from retainer (B). (A) Seal surface
CAUTION: (B) Pipe
Replace the retainer with a new one.
(1) Set a new retainer (B) to connector (A).
(2) Push the pipe into the connector completely.
NOTE:
At this time, two clicking sounds are heard.
(B) (A)

(A) (C) (B)

FU-00124 (C)

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

(A) Connector
(B) Retainer
(C) Pipe

CAUTION:
• Pull the connector to ensure it is connected
securely.
• Ensure the two retainer pawls are engaged in
their mating positions in the connector.

FU(H4DOTC)-70
 Fuel Delivery, Return and Evaporation Lines
FUEL INJECTION (FUEL SYSTEMS)

• Be sure to inspect hoses and their connec- CAUTION:

tions for any leakage of fuel. Be sure to inspect hoses and their connections
for any leakage of fuel.

(2) (3)
(1)

(A)

(B) (C) L/2

FU-00127
L
FU-00129
(A) Connector
(B) Retainer (1) Hose
(C) Pipe (2) Clip
(3) Pipe
2) Connect the fuel delivery hose and return hose
to the pipe with an overlap of 20 to 25 mm (0.79 to C: INSPECTION
0.98 in).
1) Make sure there are no cracks on the fuel pipes
Type A: When the fitting length is specified. and fuel hoses.
Type B: When the fitting length is not specified. 2) Make sure the fuel pipe and fuel hose connec-
2: 2.5±1.5 mm (0.098±0.059 in) tions are tightened firmly.
L: 22.5±2.5 mm (0.886±0.098 in)
(1) (2) (3)

Type A

Type B

FU-00128

(1) Fitting
(2) Clamp
(3) Hose

3) Connect the evaporation hose to the pipe with

an overlap of 15 to 20 mm (0.59 to 0.79 in).
L = 17.5±2.5 mm (0.689±0.098 in)

FU(H4DOTC)-71
 Fuel System Trouble in General
FUEL INJECTION (FUEL SYSTEMS)

34.Fuel System Trouble in General

A: INSPECTION
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
Inspect connections, especially ground, and tighten
❍ Defective terminal contact.
securely.
❍ Trouble in electromagnetic or electronic circuit parts. Replace fuel pump.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
Clean, correct or replace air breather tube or air vent
5) Clogged or bent air breather tube or air vent tube.
tube.
3. Gasoline smell inside of compartment
Loose joints at air breather tube, air vent tube and fuel filler
1) Retightening.
pipe.
2) Defective packing air tightness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE: level drops to about one-half. After the winter
• When the vehicle is left unattended for an ex- season, drain the water which may have accu-
tended period of time, water may accumulate in the mulated in the fuel filter and fuel tank in the man-
fuel tank. ner same as that described under Affected
To prevent water condensation. areas below.
(1) Top off the fuel tank or drain the fuel com- (4) Affected areas
pletely. When the water condensation is notched in the
(2) Drain the water condensation from the fuel fuel filter, drain the water from both the fuel filter
filter. and fuel tank or use a water removing agent (or
• Refilling the fuel tank. anti-freeze solution) in the fuel tank.
Refill the fuel tank while there is still some fuel left in • Observe the instructions, notes, etc., indicated
the tank. on the label affixed to the anti-freeze solution (wa-
• Protecting the fuel system against freezing and ter removing agent) container before use.
water condensation.
(3) Cold areas
In snow-covered areas, mountainous areas, ski-
ing areas, etc. where ambient temperatures
drop below 0°C (32°F) throughout the winter
season, use an anti-freeze solution in the cool-
ing system. Refueling will also complement the
effect of anti-freeze solution each time the fuel

FU(H4DOTC)-72