Subaru Car 1998-05

Fuel Injectors

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Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of the fuel injector-1998 engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel injector connector
     
    Fuel injector cup retaining screws
     
    Fuel injector from the fuel pipe assembly
     
    Injector O-rings and insulator. Discard the O-rings and the insulator.
     

  6.  

To install:

  1. Install or connect the following:

    New O-rings and insulators on the injector(s)
     
    Injector into the fuel pipe
     
    Fuel injector cup retaining screws and tighten to 2.1-2.9 ft. lbs. (2.9-3.9 Nm)
     
    Fuel injector electrical connector
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  



Click image to see an enlarged view

Fig. Exploded view of the fuel injector-1999-02 engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. To remove the right side injectors, remove or disconnect the following:

    Air cleaner ducts and resonator chamber, on California vehicles
     
    Mass Air Flow (MAF) sensor connector and air intake duct and air cleaner upper cover as a unit, on non-California vehicles
     
    Air cleaner element on non-California vehicles
     
    Spark plug wires from the right side spark plugs
     
    V-belt covers and power steering pump belt
     
    Power steering pump brackets-to-intake manifold bolts
     
    Power steering pump-to-bracket bolts, then position the pump on the right side wheel apron
     

  6.  
  7. To remove the injectors on the left side, remove or disconnect the following:

    Windshield washer motor electrical connector
     
    Electrical connector from the rear window washer, on station wagon only
     
    Rear window washer hose from the washer motor and plug or cap the line
     
    Two bolts that secure the washer tank to the body
     
    Washer tank and secure it out of the way
     
    Spark plug wires from the left side spark plugs
     
    Fuel pipe protector
     

  8.  
  9. Remove or disconnect the following (for either side):
    NOTE
    Automatic transaxle equipped Legacy-s may have a retaining clip that must be removed before the injector can be removed.



    Band that secures the engine harness to the fuel injector pipe, if equipped
     
    Intake manifold protector, if equipped
     
    Fuel injector electrical connector(s)
     
    Bolts that hold the fuel injector pipe (fuel rail) to the intake manifold, if applicable
     

  10.  
  11. Pull up on the injector pipe (fuel rail), then remove the fuel injector(s) from the intake manifold. Remove and discard the injector O-rings.
  12.  

To install:



Install or connect the following:
 



New injector O-rings
 
Fuel injector(s) into the intake manifold
 
Retaining clips, if applicable
 
Injector pipe (fuel rail) and secure with the retaining bolts. Tighten the bolts to 2.1-2.9 ft. lbs. (2.9-3.9 Nm).
 
Fuel injector electrical connector(s)
 
Intake manifold protector, if equipped
 
Band that secures the engine harness to the fuel injector pipe, if equipped
 

  1. To install the injectors on the left side, install or connect the following:

    Fuel pipe protector
     
    Spark plug wires to the left side spark plugs
     
    Washer tank and secure with the two mounting bolts
     
    Rear window washer hose to the washer motor
     
    Electrical connector to the rear window washer, on station wagon only
     
    Windshield washer motor electrical connector
     

  2.  
  3. To install the right side injectors, install or connect the following:

    Power steering pump into position
     
    Pump-to-bracket bolts
     
    Power steering pump brackets-to-intake manifold bolts
     
    Power steering pump belt and V-belt covers
     
    Spark plug wires to the right side spark plugs
     
    Air cleaner element, on non-California vehicles
     
    Air intake duct and upper cover and the MAF sensor connector
     
    Air cleaner ducts and resonator chamber, on California vehicles
     

  4.  

1.8L Engine


Click image to see an enlarged view

Fig. Exploded view of fuel system components-1.8L engine

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some engines, it may be necessary to remove the intake plenum to gain access to the fuel lines connecting the injectors.

  4.  
  5. Remove the fuel lines connecting the injectors.
  6.  
  7. Disconnect the fuel injector electrical harnesses.
  8.  
  9. Remove the injectors by pulling with a slight twist. Discard the gaskets and O-rings.
  10.  
  11. Remove the injector holder plate, insulator, holder and seal. Discard the insulator and seal.
  12.  
  13. Install the injectors using new gaskets, seals, insulators and O-rings. Lubricate the O-rings with clean engine oil prior to installation. Install the fuel lines connecting the injectors.
  14.  
  15. Installation is the reverse of removal. Tighten all components accordingly.
  16.  
  17. Start the engine and check for leaks.
  18.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Intake manifold
     
    Fuel pipe protector
     
    Electrical connector from the fuel injector
     
    Bolts that attach the injector pipe to the intake manifold
     
    Fuel injector while lifting up the fuel injector pipe
     

  6.  

To install:



Install or connect the following:
 



New injector O-rings
 
Remaining components in the reverse order of removal. Tighten the injector pipe bolts to 13 ft. lbs. (19 Nm).
 

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:

    Intake manifold
     
    Fuel pipe protector
     
    Electrical connector from the fuel injector
     
    Bolts that attach the injector pipe to the intake manifold
     
    Fuel injector while lifting up the fuel injector pipe
     

  6.  

To install:



Install or connect the following:
 



New injector O-rings
 
Remaining components in the reverse order of removal. Tighten the injector pipe bolts to 13 ft. lbs. (19 Nm).
 

2.5L DOHC
  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable. Drain the radiator, as required.
  4.  
  5. If removing the right side injectors, remove the air cleaner upper cover and air intake boot. Remove the air cleaner element. Remove the coolant filler tank.
  6.  
  7. If removing the right side injectors, remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt.
  8.  
  9. If removing the right side injectors, disconnect the power steering switch connector. Remove the bolts that retain the power steering hoses to the intake manifold protector. Do not disconnect the power steering hoses. Remove the bolts which retain the power steering pump to the bracket. Remove the reservoir tank from the bracket, by pulling upward. Place the power steering pump and tank assembly to the side.
  10.  
  11. If removing the left side injectors, remove the intake manifold.
  12.  
  13. Remove the fuel line protector cover(s).
  14.  
  15. Disconnect the electrical connector from the fuel injector.
  16.  
  17. If removing the left side injectors, disconnect the connector from the purge control solenoid valve and remove the valve.
  18.  
  19. Remove the harness band that holds the engine harness to the fuel injector line.
  20.  
  21. Remove the bolts that hold the fuel injector line to the intake manifold.
  22.  
  23. Remove the fuel injector while lifting up the fuel injector line.
  24.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new O-rings and insulators.
  4.  
  5. Start the engine and check for leaks, correct as required.
  6.  

  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the collector cover.
  6.  
  7. If removing the right side injectors, drain the radiator, as required and the coolant filler tank.
  8.  
  9. Disconnect the electrical connector from the fuel injector.
  10.  
  11. Remove the screw and then remove the fuel injector.
  12.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new O-rings and insulators.
  4.  
  5. Start the engine and check for leaks, correct as required.
  6.  

  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If removing the left side injectors, remove the intake manifold.
  6.  
  7. Disconnect the electrical connector from the fuel injector.
  8.  
  9. Remove the screw and then remove the fuel injector.
  10.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new O-rings.
  4.  
  5. Start the engine and check for leaks, correct as required.
  6.  

2.5L Engine


Click image to see an enlarged view

Fig. Fuel injector assembly-2.5L engine (1997)



Click image to see an enlarged view

Fig. Unfasten the fuel injector wire harness from the top of the injector assembly



Click image to see an enlarged view

Fig. Remove the fuel injector cover retainer screw from one side of the injector . . .



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Fig. . . . then unfasten the other retainer screw



Click image to see an enlarged view

Fig. Lift the cover off . . .



Click image to see an enlarged view

Fig. . . . and remove the seal



Click image to see an enlarged view

Fig. Carefully remove the fuel injector from the cylinder head



Click image to see an enlarged view

Fig. Remove the lower injector O-ring



Click image to see an enlarged view

Fig. If necessary, remove a stuck O-ring with a pick tool



Click image to see an enlarged view

Fig. Remove the upper O-ring from the injector. Discard all used O-rings


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the fuel injector electrical harness.
  6.  
  7. Remove the fuel injection cover.
  8.  
  9. Remove the fuel injector from the fuel pipe assembly.
  10.  
  11. Remove and discard the fuel injector O-rings and insulators,
  12.  
  13. Installation is the reverse of removal. Install the injector with two new O-rings and a new insulator. Tighten the bolts to 24 inch lbs. (3 Nm).
  14.  
  15. Start the engine and check for leaks.
  16.  

2.5L SOHC
  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If removing the right side injectors, remove the air intake chamber and air cleaner case. To remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt.
  6.  
  7. If removing the right side injectors, remove the bolts that retain the power steering hoses to the intake manifold protector. Do not disconnect the power steering hoses. Remove the bolts which retain the power steering pump to the bracket. Disconnect the power steering pump switch connector. Remove the reservoir tank from the bracket, by pulling upward. Place the power steering pump and tank assembly to the side.
  8.  
  9. Remove the spark plug wires.
  10.  
  11. Remove the fuel line protector cover(s).
  12.  
  13. Disconnect the electrical connector from the fuel injector.
  14.  
  15. Remove the harness band that holds the engine harness to the fuel injector line.
  16.  
  17. Remove the bolts that hold the fuel injector line to the intake manifold.
  18.  
  19. Remove the fuel injector while lifting up the fuel injector line.
  20.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new O-rings.
  4.  
  5. Start the engine and check for leaks, correct as required.
  6.  

  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If removing the right side injectors, remove the air intake duct and air cleaner case.
  6.  
  7. If removing the left side injectors, remove the battery.
  8.  
  9. Remove the spark plug wires.
  10.  
  11. Remove the fuel line protector cover(s).
  12.  
  13. Disconnect the electrical connector from the fuel injector.
  14.  
  15. Remove the harness band that holds the engine harness to the fuel injector line.
  16.  
  17. Remove the bolts that hold the fuel injector line to the intake manifold.
  18.  
  19. Remove the fuel injector while lifting up the fuel injector line.
  20.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new O-rings.
  4.  
  5. Start the engine and check for leaks, correct as required.
  6.  

  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If removing the right side injectors, remove the resonator chamber. Remove the number one and three spark plug wires.
  6.  
  7. If removing the right side injectors, remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt. Remove the bolts that retain the power steering hoses to the intake manifold protector. Do not disconnect the power steering hoses. Remove the bolts which retain the power steering pump to the bracket. Disconnect the power steering pump switch connector. Remove the reservoir tank from the bracket, by pulling upward. Place the power steering pump and tank assembly to the side.
  8.  
  9. If removing the left side injectors, remove the two bolts that retain the washer fluid tank to its mounting. Disconnect the electrical connector from the front window washer motor. Disconnect the electrical connector and the washer hose from the rear gate glass washer motor. Position the tank to the side. Remove the number two and four spark plug wires.
  10.  
  11. Remove the fuel line protector cover(s).
  12.  
  13. Disconnect the electrical connector from the fuel injector.
  14.  
  15. Remove the bolts that hold the fuel injector line to the intake manifold.
  16.  
  17. Remove the fuel injector retaining clip. Remove the fuel injector while lifting up the fuel injector line.
  18.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new O-rings.
  4.  
  5. Start the engine and check for leaks, correct as required.
  6.  

3.0L DOHC
  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the collector cover.
  6.  
  7. If removing the right side injectors, remove the air cleaner case.
  8.  
  9. If removing the left side injectors, remove the battery. Remove the alternator harness from the left side fuel line protector cover.
  10.  
  11. Remove the fuel line protector cover(s).
  12.  
  13. Disconnect the electrical connector from the fuel injector.
  14.  
  15. Remove the engine harness from the fuel injector line.
  16.  
  17. Remove the bolt that hold the fuel injector line to the intake manifold.
  18.  
  19. Remove the fuel injector while lifting up the fuel injector line.
  20.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new O-rings and insulators.
  4.  
  5. Start the engine and check for leaks, correct as required.
  6.  

3.3L Engine


Click image to see an enlarged view

Fig. Exploded view of fuel system components-3.3L engine


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the collector cover.
  6.  
  7. Remove the air duct between the throttle body and mass airflow sensor.
  8.  
  9. Remove the retainer bolts attaching the power steering hose to the collector and position the hose out of the way.
  10.  
  11. Disconnect the fuel injector electrical harness.
  12.  
  13. Remove the two screws securing the injector cover, then remove the cover.
  14.  
  15. Pull the injector out while rotating it.
  16.  
  17. Remove and discard the fuel injector O-rings.
  18.  
  19. Installation is the reverse of removal. Install the fuel injector using O-rings coated with clean engine oil.
  20.  
  21. Pressurize the fuel system and verify that there are no leaks.
  22.  

Except 2.0L Engine
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. To remove the right side injectors, remove or disconnect the following:

    Air cleaner ducts and resonator chamber, on California vehicles
     
    Mass Air Flow (MAF) sensor connector and air intake duct and air cleaner upper cover as a unit, on non-California vehicles
     
    Air cleaner element
     
    Spark plug wires from the right side spark plugs
     
    V-belt covers and power steering pump belt
     
    Power steering pump brackets-to-intake manifold bolts
     
    Power steering pump-to-bracket bolts, then position the pump on the right side wheel apron
     

  6.  
  7. To remove the injectors on the left side, remove or disconnect the following:

    Windshield washer motor electrical connector
     
    Electrical connector from the rear window washer, on station wagon only
     
    Rear window washer hose from the washer motor and plug or cap the line
     
    Two bolts that secure the washer tank to the body
     
    Washer tank and secure it out of the way
     
    Spark plug wires from the left side spark plugs
     
    Fuel pipe protector
     

  8.  
  9. Remove or disconnect the following (for either side):
    NOTE
    Automatic transmission equipped Legacy-s may have a retaining clip that must be removed before the injector can be removed.



    Band that secures the engine harness to the fuel injector pipe, if equipped
     
    Intake manifold protector, if equipped
     
    Fuel injector electrical connector(s)
     
    Bolts that hold the fuel injector pipe (fuel rail) to the intake manifold, if applicable
     

  10.  
  11. Pull up on the injector pipe (fuel rail), then remove the fuel injector(s) from the intake manifold. Remove and discard the injector O-rings.
  12.  

To install:



Install or connect the following:
 



New injector O-rings
 
Fuel injector(s) into the intake manifold
 
Retaining clips, if applicable
 
Injector pipe (fuel rail) and secure with the retaining bolts. Tighten the bolts to 14 ft. lbs. (19 Nm).
 
Fuel injector electrical connector(s)
 
Intake manifold protector, if equipped
 
Band that secures the engine harness to the fuel injector pipe, if equipped
 

  1. To install the injectors on the left side, install or connect the following:

    Fuel pipe protector
     
    Spark plug wires to the left side spark plugs
     
    Washer tank and secure with the two mounting bolts
     
    Rear window washer hose to the washer motor
     
    Electrical connector to the rear window washer, on station wagon only
     
    Windshield washer motor electrical connector
     

  2.  
  3. To install the right side injectors, install or connect the following:

    Power steering pump into position
     
    Pump-to-bracket bolts
     
    Power steering pump brackets-to-intake manifold bolts
     
    Power steering pump belt and V-belt covers
     
    Spark plug wires to the right side spark plugs
     
    Air cleaner element
     
    Air intake duct and upper cover and the MAF sensor connector
     
    Air cleaner ducts and resonator chamber, on California vehicles
     

  4.  

Except 2.0L Engines


Click image to see an enlarged view

Fig. Exploded view of the fuel injector

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. To remove the right side injectors, remove or disconnect the following:

    Air cleaner ducts and resonator chamber, on California vehicles
     
    Mass Air Flow (MAF) sensor connector and air intake duct and air cleaner upper cover as a unit, on non-California vehicles
     
    Air cleaner element
     
    Spark plug wires from the right side spark plugs
     
    V-belt covers and power steering pump belt
     
    Power steering pump brackets-to-intake manifold bolts
     
    Power steering pump-to-bracket bolts, then position the pump on the right side wheel apron
     

  6.  
  7. To remove the injectors on the left side, remove or disconnect the following:

    Windshield washer motor electrical connector
     
    Electrical connector from the rear window washer, on station wagon only
     
    Rear window washer hose from the washer motor and plug or cap the line
     
    Two bolts that secure the washer tank to the body
     
    Washer tank and secure it out of the way
     
    Spark plug wires from the left side spark plugs
     
    Fuel pipe protector
     

  8.  
  9. Remove or disconnect the following (for either side):

    Band that secures the engine harness to the fuel injector pipe, if equipped
     
    Intake manifold protector, if equipped
     
    Fuel injector electrical connector(s)
     
    Bolts that hold the fuel injector pipe (fuel rail) to the intake manifold, if applicable
     

  10.  


NOTE
Automatic transaxle equipped Legacy-s may have a retaining clip that must be removed before the injector can be removed.

  1. Pull up on the injector pipe (fuel rail), then remove the fuel injector(s) from the intake manifold. Remove and discard the injector O-rings.
  2.  

To install:



Install or connect the following:
 



New injector O-rings
 
Fuel injector(s) into the intake manifold
 
Retaining clips, if applicable
 
Injector pipe (fuel rail) and secure with the retaining bolts. Tighten the bolts to 14 ft. lbs. (19 Nm).
 
Fuel injector electrical connector(s)
 
Intake manifold protector, if equipped
 
Band that secures the engine harness to the fuel injector pipe, if equipped
 

  1. To install the injectors on the left side, install or connect the following:

    Fuel pipe protector
     
    Spark plug wires to the left side spark plugs
     
    Washer tank and secure with the two mounting bolts
     
    Rear window washer hose to the washer motor
     
    Electrical connector to the rear window washer, on station wagon only
     
    Windshield washer motor electrical connector
     

  2.  
  3. To install the right side injectors, install or connect the following:

    Power steering pump into position
     
    Pump-to-bracket bolts
     
    Power steering pump brackets-to-intake manifold bolts
     
    Power steering pump belt and V-belt covers
     
    Spark plug wires to the right side spark plugs
     
    Air cleaner element
     
    Air intake duct and upper cover and the MAF sensor connector
     
    Air cleaner ducts and resonator chamber, on California vehicles
     

  4.  

 
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