Subaru Forester 1998-05

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



  1. Properly relieve the fuel system pressure.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Electrical connector from injector
     
    Fuel injector from fuel rail
     
    Fuel lines from the fuel rail
     
    Fuel rail.
     

  4.  

To install:

  1. Replace old O-rings and insulators with new ones.
  2.  
  3. Install or connect the following:

    Fuel rail
     
    Fuel lines to the fuel rail
     
    Fuel injector from fuel rail. Torque the mounting bolts to 2.5 ft. lbs. (3.4 Nm).
     
    Electrical connector to injector
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. View of fuel injector removal-1998 models

     

  4.  

DOHC (Turbo) Engines
  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable. Remove the collector cover. 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.  
  25. Disconnect and plug the fuel supply and return lines from the fuel rail.
  26.  

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.  

SOHC (Non-Turbo) Engines
  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, if necessary
     
    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.  
  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.  
  13. Disconnect and plug the fuel supply and return lines from the fuel rail.
  14.  

To install:


NOTE
Always replace the O-rings and fuel rail insulators with new ones.



Install or connect the following:
 



Fuel lines to the fuel rail
 
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, if necessary
     
    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

    Click image to see an enlarged view

    Fig. View of fuel injector removal on 1999-2004 SOHC models

     

  4.  

  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. 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 battery. 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.  
  19. Disconnect and plug the fuel supply and return lines from the fuel rail.
  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.  

 
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