SUBARU LEGACY 1996 Service Repair Manual

2. FWD MODEL
B2M0631A

1Heat seated cover


2Fuel tank band


3Protector


4Protector bracket


5Fuel tank


6Fuel pump gasket


7Fuel pump ASSY


8Clamp


9Clip


10Fuel delivery hose A


11Fuel return hose A


12Evaporation hose A


13Fuel pipe ASSY

14Fuel delivery hose B


15Fuel return hose B


16Evaporation hose B


17Plate


18Roll over valve
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
T2: 7.4±0.2 (0.75±0.2, 5.4±1.4)
T3: 18±5 (1.8±0.5, 13.0±3.6)
T4: 33±10 (3.4±1.0, 25±7)
4
2-8COMPONENT PARTS
1. Fuel Tank

3. 2200 cc AWD MODEL
B2M0975A
5
2-8COMPONENT PARTS
1. Fuel Tank

1Heat sealed cover


2Fuel tank band


3Protector LH


4Protector RH


5Fuel tank


6Pressure control solenoid valve bracket


7Pressure control solenoid valve


8Evaporation hose G


9Evaporation pipe A


10Fuel pump gasket


11Fuel pump ASSY


12Fuel cut valve gasket


13Fuel cut valve


14Evaporation hose C


15Evaporation hose A


16Clip


17Joint pipe


18Evaporation hose B


19Evaporation pipe ASSY

20Evaporation hose D


21Evaporation hose E


22Clamp


23Jet pump hose A


24Fuel delivery hose A


25Fuel return hose A


26Fuel pipe ASSY


27Jet pump hose B


28Fuel delivery hose B


29Fuel return hose B


30Evaporation hose F


31Fuel sub meter gasket


32Jet pump filter


33Fuel sub meter unit
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
T3: 33±10 (3.4±1.0, 25±7)
6
2-8COMPONENT PARTS
1. Fuel Tank

2. Fuel Line
1. 2200 cc FWD AND 2500 cc MODEL
B2M0046A

1Clamp


2Fuel delivery hose A


3Fuel filter bracket


4Fuel filter holder


5Fuel filter cup


6Fuel filter


7Evaporation hose


8Clip


9Fuel delivery hose B

10Fuel return hose


11Air vent hose


12Canister


13Canister hose A


14Two-way valve


15Canister hose B


16Canister hose C


17Canister bracket


18Fuel pipe ASSY
7
2-8COMPONENT PARTS
2. Fuel Line

2. 2200 cc AWD MODEL
B2M0974A
8
2-8COMPONENT PARTS
2. Fuel Line

1Clamp


2Fuel delivery hose A


3Fuel filter bracket


4Fuel filter holder


5Fuel filter cup


6Fuel filter


7Evaporation hose


8Clip


9Fuel delivery hose B


10Fuel return hose


11Roll over valve


12Roll over valve bracket


13Evaporation hose H


14Evaporation hose I


15Evaporation pipe B


16Canister hose A


17Canister hose B


18Canister holder


19Canister upper bracket


20Cushion rubber


21Canister lower bracket


22Canister


23Fuel pipe ASSY


24Fuel filler valve


25Fuel filler pipe


26Packing

27Ring A


28Ring B


29Fuel filler cap


30Fuel filler pipe protector


31Fuel tank pressure sensor


32Fuel tank pressure sensor hose A


33Fuel tank pressure sensor bracket


34Grommet


35Fuel tank pressure sensor hose B


36Air ventilator hose A


37Air ventilator pipe A


38Air ventilator hose B


39Air ventilator pipe B


40Air ventilator pipe protector


41Vent control solenoid valve


42Vent control solenoid valve hose


43Air filter hose A


44Air filter hose B


45Air filter


46Tapping screw
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 23±7 (2.3±0.7, 17±5.1)
T2: 25±7 (2.5±0.7, 18±5.1)
9
2-8COMPONENT PARTS
2. Fuel Line

1. Precautions
WARNING:
Place “No fire” signs near the working area.
Disconnect ground terminal from battery.
Be careful not to spill fuel on the floor.
G2M0340
A: RELEASING OF FUEL PRESSURE
1) Take off floor mat.
2) Remove access hole lid.
B2M0047
3) Disconnect connector from fuel pump.
4) Start the engine, and run it until it stalls.
5) After the engine stalls, crank it for five more seconds.
6) Turn ignition switch OFF.
G2M0340
B: DRAINING OF FUEL
1) Remove rear seat and seat back.
2) Remove access hole lid.
B2M0047
3) Disconnect connector from fuel pump.
4) Release fuel pressure. <Ref. to 2-8 [W1A0].>
10
2-8SERVICE PROCEDURE
1. Precautions

B2M0048A
5) Disconnect fuel delivery hose
1and return hose
2.
6) Disconnect jet pump hose

3. (AWD model)
G2M0343
7) Remove nuts which install fuel pump assembly onto
fuel tank.
G2M0344
8) Take off fuel pump from fuel tank.
G2M0345
9) Drain fuel from fuel tank by using a hand pump.
WARNING:
Do not use a motor pump when draining fuel.
G2M0346
10) After draining fuel, reinstall fuel pump.
Tighten nuts in numerical sequence shown in Figure to
specified torque.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
11
2-8SERVICE PROCEDURE
1. Precautions

B2M0049
11) On AWD model, after removing fuel sub meter unit,
drain fuel from there.
WARNING:
Do not use a motor pump when draining fuel.
2. On-Car Services
A: MEASUREMENT OF FUEL PRESSURE
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Connect connector to fuel pump.
G2M0347
3) Disconnect fuel delivery hoses from fuel filter, and con-
nect fuel pressure gauge.
G2M0348
4) Start the engine.
5) Measure fuel pressure while disconnecting pressure
regulator vacuum hose from collector chamber.
Fuel pressure:
235 — 265 kPa (2.4 — 2.7 kg/cm
2, 34 — 38 psi)
6) After connecting pressure regulator vacuum hose, mea-
sure fuel pressure.
Fuel pressure:
177 — 206 kPa (1.8 — 2.1 kg/cm
2, 26 — 30 psi)
WARNING:
Before removing fuel pressure gauge, release fuel
pressure.
NOTE:
If out of specification as measured at step 6), check or
replace pressure regulator and pressure regulator vacuum
hose.
12
2-8SERVICE PROCEDURE
1. Precautions - 2. On-Car Services

B2M0049
11) On AWD model, after removing fuel sub meter unit,
drain fuel from there.
WARNING:
Do not use a motor pump when draining fuel.
2. On-Car Services
A: MEASUREMENT OF FUEL PRESSURE
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Connect connector to fuel pump.
G2M0347
3) Disconnect fuel delivery hoses from fuel filter, and con-
nect fuel pressure gauge.
G2M0348
4) Start the engine.
5) Measure fuel pressure while disconnecting pressure
regulator vacuum hose from collector chamber.
Fuel pressure:
235 — 265 kPa (2.4 — 2.7 kg/cm
2, 34 — 38 psi)
6) After connecting pressure regulator vacuum hose, mea-
sure fuel pressure.
Fuel pressure:
177 — 206 kPa (1.8 — 2.1 kg/cm
2, 26 — 30 psi)
WARNING:
Before removing fuel pressure gauge, release fuel
pressure.
NOTE:
If out of specification as measured at step 6), check or
replace pressure regulator and pressure regulator vacuum
hose.
12
2-8SERVICE PROCEDURE
1. Precautions - 2. On-Car Services