fuel SUBARU LEGACY 1995 Service User Guide

1. Engine Cooling System
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of engine coolant pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair ignition control system.

h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair fuel injection system.

k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
q. Malfunction of electric fanInspect radiator fan relay, engine coolant temperature
sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from engine coolant pump Replace.
c. Leakage from engine coolant pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective engine coolant pump bearing Replace engine coolant pump.
d. Defective engine coolant pump mechanical seal Replace engine coolant pump.
19
2-5DIAGNOSTICS
1. Engine Cooling System

1. Collector Chamber and Intake
Manifold
B2M0338A

1Intake manifold gasket RH


2Intake manifold gasket LH


3Fuel injector pipe insulator


4Fuel injector pipe


5O-ring A


6O-ring B


7Fuel injector


8Insulator


9Fuel injector cap


10Gasket


11Engine coolant hose B


12Air by-pass hose


13Idle air control solenoid valve


14Engine coolant hose A

15Nipple (AT model)


16Plug


17PCV valve


18Purge control solenoid valve


19Nipple


20BPT


21BPT holder bracket


22Back pressure hose


23EGR vacuum hose A


24EGR vacuum pipe


25EGR vacuum hose C


26EGR valve


27Gasket


28EGR vacuum hose B

29EGR solenoid valve


30EGR pipe


31Intake manifold
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
T2: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T3: 16±1.5 (1.6±0.15, 11.6±1.1)
T4: 19±1 (1.9±0.1, 13.7±0.7)
T5: 19±1.5 (1.9±0.15, 13.7±1.1)
T6: 23±3 (2.3±0.3, 16.6±2.2)
T7: 25±2 (2.5±0.2, 18.1±1.4)
T8: 34±2 (3.5±0.2, 25.3±1.4)
2
2-7COMPONENT PARTS
1. Collector Chamber and Intake Manifold

B2M0154
4. Intake Manifold
A: REMOVAL
1) Release fuel pressure.
2) Disconnect connector from mass air flow sensor.
3) Remove air intake duct, air cleaner upper cover and air
cleaner element.
G2M0280
4) Disconnect accelerator cable
1.
5) Disconnect cruise control cable

2. (With cruise control
model)
B2M0334
6) Disconnect hoses from pressure sources switching
solenoid valve.
G2M0286
7) Remove power steering pump from bracket.
(1) Loosen lock bolt and slider bolt, and remove front
side V-belt.
B2M0340
(2) Remove pipe with bracket from intake manifold.
8
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0346
17) Disconnect connector from knock sensor.
G2M0416
18) Disconnect connector from camshaft position sensor.
G2M0408
19) Disconnect connector from crankshaft position sensor.
G2M0091
20) Disconnect connector from oil pressure switch.
G2M0296
21) Disconnect fuel hoses from pipes.
WARNING:
Catch fuel from hoses in a container.
11
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0159
22) Remove bolts which hold intake manifold onto cylinder
heads.
B2M0160
23) Remove intake manifold.
B2M0347A
B: DISASSEMBLY
1) Disconnect connectors from throttle position sensor,
ignition coil, fuel injectors, idle air control solenoid valve,
purge control solenoid valve and EGR solenoid valve.
2) Remove engine harness from intake manifold.


1EGR solenoid valve


2Throttle position sensor


3Idle air control solenoid valve


4Purge control solenoid valve


5Harness band
B2M0157
3) Remove throttle body from intake manifold.
B2M0161A
4) Remove fuel pipes, etc. from intake manifold.


1Pressure regulator


2Purge control solenoid valve


3Fuel pipe ASSY
12
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0161A
C: ASSEMBLY
1) Assemble fuel pipes, etc. to intake manifold.


1Pressure regulator


2Purge control solenoid valve


3Fuel pipe ASSY
B2M0157
2) Assemble throttle body to intake manifold.
CAUTION:
Replace gasket with a new one.
Tightening torque:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
B2M0347A
3) Install engine harness onto intake manifold.
4) Connect connectors to throttle position sensor, ignition
coil, fuel injectors, idle air control solenoid valve, purge
control solenoid valve and EGR solenoid valve.


1EGR solenoid valve


2Throttle position sensor


3Idle air control solenoid valve


4Purge control solenoid valve


5Harness band
B2M0159
D: INSTALLATION
1) Install intake manifold onto cylinder heads.
CAUTION:
Always use new gaskets.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G2M0296
2) Connect fuel hoses.
13
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0362
3) Remove pressure sources switching solenoid valve
from bracket.
4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
G2M0398
14. Fuel Injector
A: REMOVAL AND INSTALLATION
1) Release fuel pressure.

2) Disconnect connector from fuel injector.
G2M0431
3) Remove fuel injector from fuel pipe assembly.
B2M0169A
4) Installation is in the reverse order of removal.
CAUTION:
Replace O-rings and insulator.
Tightening torque:
T: 3.4±0.5 N⋅m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)


1O-ring B


2O-ring A


3Fuel injector


4Insulator


5Fuel injector cup
G6M0095
15. Engine Control Module
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
25
2-7SERVICE PROCEDURE
13. Pressure Sources Switching Solenoid Valve (AT model) - 14. Fuel Injector

B2M0362
3) Remove pressure sources switching solenoid valve
from bracket.
4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
G2M0398
14. Fuel Injector
A: REMOVAL AND INSTALLATION
1) Release fuel pressure.

2) Disconnect connector from fuel injector.
G2M0431
3) Remove fuel injector from fuel pipe assembly.
B2M0169A
4) Installation is in the reverse order of removal.
CAUTION:
Replace O-rings and insulator.
Tightening torque:
T: 3.4±0.5 N⋅m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)


1O-ring B


2O-ring A


3Fuel injector


4Insulator


5Fuel injector cup
G6M0095
15. Engine Control Module
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
25
2-7SERVICE PROCEDURE
13. Pressure Sources Switching Solenoid Valve (AT model) - 14. Fuel Injector

B2M0362
3) Remove pressure sources switching solenoid valve
from bracket.
4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
G2M0398
14. Fuel Injector
A: REMOVAL AND INSTALLATION
1) Release fuel pressure.

2) Disconnect connector from fuel injector.
G2M0431
3) Remove fuel injector from fuel pipe assembly.
B2M0169A
4) Installation is in the reverse order of removal.
CAUTION:
Replace O-rings and insulator.
Tightening torque:
T: 3.4±0.5 N⋅m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)


1O-ring B


2O-ring A


3Fuel injector


4Insulator


5Fuel injector cup
G6M0095
15. Engine Control Module
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
25
2-7SERVICE PROCEDURE
13. Pressure Sources Switching Solenoid Valve (AT model) - 14. Fuel Injector

G6M0095
16. Main Relay
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B5M0024A
2) Remove lower cover and then disconnect connectors.
3) Lower transmission control module.
4) Remove the front pillar lower trim.

5) Remove fuse box mounting nuts.
6) Lower fuse box.
7) Remove fuse box mounting bracket.
G2M0438
8) Remove screw which retains bracket of main relay
1
and fuel pump relay
2.
9) Disconnect connector from main relay.
G2M0438
10) Installation is in the reverse order of removal.


1Main relay


2Fuel pump relay
27
2-7SERVICE PROCEDURE
16. Main Relay