filter SUBARU LEGACY 1995 Service User Guide

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.
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.
8
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.
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.
8
2-8SERVICE PROCEDURE
1. Precautions - 2. On-Car Services

G2M0358
5) Insert air vent hose approximately 25 to 30 mm (0.98 to
1.18 in) into the lower end of air vent pipe and hold clip.


1Hose


2Clip


3Pipe
L=25—30 mm (0.98—1.18 in)
G2M0361
6) Install fuel filler pipe protector.
7) Install right rear wheel.
5. Fuel Filter
A: REMOVAL
1) Release fuel pressure.
G2M0347
2) Disconnect fuel delivery hoses from fuel filter.
3) Remove filter from holder.
B: INSPECTION
1) Check the inside of fuel filter for dirt and water sedi-
ment.
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
inlet port.
14
2-8SERVICE PROCEDURE
4. Fuel Filler Pipe - 5. Fuel Filter

G2M0358
5) Insert air vent hose approximately 25 to 30 mm (0.98 to
1.18 in) into the lower end of air vent pipe and hold clip.


1Hose


2Clip


3Pipe
L=25—30 mm (0.98—1.18 in)
G2M0361
6) Install fuel filler pipe protector.
7) Install right rear wheel.
5. Fuel Filter
A: REMOVAL
1) Release fuel pressure.
G2M0347
2) Disconnect fuel delivery hoses from fuel filter.
3) Remove filter from holder.
B: INSPECTION
1) Check the inside of fuel filter for dirt and water sedi-
ment.
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
inlet port.
14
2-8SERVICE PROCEDURE
4. Fuel Filler Pipe - 5. Fuel Filter

C: INSTALLATION
CAUTION:
If fuel hoses are damaged at the connecting portion,
replace it with a new one.
If clamps are badly damaged, replace with new ones.
G2M0347
1) Installation is in the reverse order of removal.
2) Tighten hose clamp screws.
Tightening torque:
1.0
+0.5
0N⋅m (0.1+0.05
0kg-m, 0.7+0.4
0ft-lb)
B2M0048A
6. Fuel Pump
A: REMOVAL
1) Release fuel pressure.
2) Disconnect fuel delivery hose

1and return hose
2.
3) Disconnect jet pump hose

3. (AWD model)
G2M0343
4) Remove nuts which install fuel pump assembly onto
fuel tank.
G2M0344
5) Take off fuel pump from fuel tank.
15
2-8SERVICE PROCEDURE
5. Fuel Filter - 6. Fuel Pump

C: INSTALLATION
CAUTION:
If fuel hoses are damaged at the connecting portion,
replace it with a new one.
If clamps are badly damaged, replace with new ones.
G2M0347
1) Installation is in the reverse order of removal.
2) Tighten hose clamp screws.
Tightening torque:
1.0
+0.5
0N⋅m (0.1+0.05
0kg-m, 0.7+0.4
0ft-lb)
B2M0048A
6. Fuel Pump
A: REMOVAL
1) Release fuel pressure.
2) Disconnect fuel delivery hose

1and return hose
2.
3) Disconnect jet pump hose

3. (AWD model)
G2M0343
4) Remove nuts which install fuel pump assembly onto
fuel tank.
G2M0344
5) Take off fuel pump from fuel tank.
15
2-8SERVICE PROCEDURE
5. Fuel Filter - 6. Fuel Pump

8. Fuel Delivery, Return and
Evaporation Lines
A: REMOVAL
1) Release fuel pressure.
2) Remove inner trim, insulator and rear seat.
3) Remove fuel delivery pipes and hoses, fuel return pipes
and hoses, and evaporation pipes and hoses.
B2M0050A

1Canister


2Fuel tank


3Fuel pump

4Fuel cut valve (AWD)


5Fuel sub meter unit (AWD)


6Fuel filter
18
2-8SERVICE PROCEDURE
8. Fuel Delivery, Return and Evaporation Lines

1. Fuel System
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.

Defective terminal contact.Inspect connections, especially ground, and tighten
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.
5) Clogged or bent air breather tube or air vent tube. Clean, correct or replace air breather tube or air vent tube.
3. Gasoline smell inside of compartment
1)Loose joints at air breather tube, air vent tube and fuel filler
pipe.Retightening.
2) Defective packing air tightness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4. Defective fuel meter indicator
1) Defective operation of fuel meter unit. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
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 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:
1) 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 water which may have accumulated in the fuel filter and fuel
tank in the manner same as that described under affected areas as below.
2) Affected areas
When water condensation is notched in the fuel filter, drain 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.
22
2-8DIAGNOSTICS
1. Fuel System

10. Transfer and Extension
B3M0375A

1Snap ring


2Pressure plate


3Drive plate


4Driven plate


5Thrust needle bearing


6Snap ring


7Spring retainer


8Lathe cut seal ring


9Transfer clutch piston


10Lathe cut seal ring


11Needle bearing


12Rear drive shaft


13Ball bearing

14Seal ring


15Vehicle speed sensor 1 (AWD only)


16Transfer clutch pipe


17Duty sol. C (Transfer clutch)


18Gasket


19Plate


20Filter


21Gasket


22Roller bearing


23Extension case


24Oil seal


25Dust seal


26Seal transfer piston

27O-ring


28Test plug


29O-ring


30Clip


31Transfer valve body


32Clip


33Stay
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 7±1 (0.7±0.1, 5.1±0.7)
T2: 8±1 (0.8±0.1, 5.8±0.7)
T3: 13±1 (1.3±0.1, 9.4±0.7)
T4: 25±2 (2.5±0.2, 18.1±1.4)
20
3-2COMPONENT PARTS
10. Transfer and Extension

G3M0371
5) Remove the snap ring. Then remove the speedometer
driven gear.
G3M0372
6) Remove vehicle speed sensor 2.
7) Tap out the speedometer shaft to the outside of the
case, and remove the oil seal.
G3M0373
5. EXTENSION SECTION
1) Take out the transfer clutch by lightly tapping the end of
the rear drive shaft.
CAUTION:
Be careful not to damage the oil seal in the extension.
G3M0867
2) Remove duty solenoid C, transfer valve body and the
transfer pipe.
CAUTION:
Take out the inlet filter.
Do not damage the O-ring.
Be careful not to bend the pipe.
B3M0831A
3) Take out the roller bearing inner race with ST.
ST 398527700 PULLER
4) Take out the roller bearing outer race with ST.
NOTE:
Hook ST in the inner side of the roller bearing outer race.
ST 398527700 PULLER
58
3-2SERVICE PROCEDURE
4. Overall Transmission