SUBARU LEGACY 1996 Service Repair Manual

B2M0741
2) Install rear oxygen sensor.
Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Lower the vehicle.
4) Connect connector to rear oxygen sensor.
23
2-7SERVICE PROCEDURE
8. Rear Oxygen Sensor

B2M0162
9. Throttle Position Sensor
A: REMOVAL AND INSTALLATION
1) Disconnect connector from throttle position sensor.
2) Remove throttle position sensor holding screws, and
remove it.
3) Installation is in the reverse order of removal.
Tightening torque:
2.2±0.2 N⋅m (0.22±0.02 kg-m, 1.6±0.1 ft-lb)
CAUTION:
When installing throttle position sensor, adjust to the
specified data.
B2M0163
B: ADJUSTMENT
1) Turn ignition switch to OFF.
2) Loosen throttle position sensor holding screws.
G2M0415
3) When using voltage meter;
(1) Take out ECM.
(2) Turn ignition switch to ON.
(3) Adjust throttle position sensor so that signal voltage
to ECM may be in specification.
Connector & Terminal / Specified voltage
(B84) No. 24 — (B84) No. 25 / 0.45 — 0.55 V
[Fully closed.]
(4) Tighten throttle position sensor holding screws.
G2M0096
4) When using Subaru Select Monitor;
(1) Connect Subaru Select Monitor to the data link con-
nector.
(2) Turn ignition switch to ON and SSM switch to ON.
(3) Select mode “F10”.
(4) Adjust throttle position sensor to specified data.
Condition / Specified data.
Throttle fully closed / 0.50 V
(5) Tighten throttle position sensor holding screws.
24
2-7SERVICE PROCEDURE
9. Throttle Position Sensor

G2M0416
10. Camshaft Position Sensor
A: REMOVAL AND INSTALLATION
1) Disconnect connector from camshaft position sensor.
G2M0417
2) Remove camshaft position sensor from camshaft sup-
port LH.
3) 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)
B2M0355
11. Pressure Sensor (AT model)
A: REMOVAL AND INSTALLATION
1) Disconnect connector from pressure sensor.
2) Disconnect hose from pressure sensor.
B2M0356
3) Remove pressure sensor 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)
25
2-7SERVICE PROCEDURE
10. Camshaft Position Sensor - 11. Pressure Sensor (AT model)

B2M0164
12. Idle Air Control Solenoid Valve
A: REMOVAL AND INSTALLATION
1) Disconnect connector from idle air control solenoid
valve.
B2M0165A
2) Disconnect engine coolant hoses
1from idle air con-
trol solenoid valve.
3) Disconnect air by-pass hose

2from idle air control
solenoid valve.
B2M0166
4) Remove idle air control solenoid valve from throttle
body.
5) Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
B2M0357
B: CLEANING
1) Start and warm-up the engine until radiator fan oper-
ates.
2) Hold throttle valve so that engine speed is at 2,000 rpm.
B2M0359
3) Disconnect by-pass hose from idle air control solenoid
valve.
26
2-7SERVICE PROCEDURE
12. Idle Air Control Solenoid Valve

B2M0358
4) Slowly pour one can (16 oz) of cleaner into by-pass air
hole.
Cleaner:
Part No. 1050002 GM Top Engine Cleaner
Part No. X66-A AC Delco Carburetor Tune-up
Conditioner
5) Leave the engine running for five minutes.
NOTE:
White smoke comes out of the muffler until the cleaner is
used up.
6) Stop the engine.
B2M0359
7) Release the throttle valve.
8) Connect by-pass hose to idle air control solenoid valve.
G2M0096
9) Check duty ratio of idle air control solenoid valve with
Subaru Select Monitor.
(1) Connect Subaru Select Monitor to the data link con-
nector.
(2) Start the engine and turn Subaru Select Monitor
switch to ON.
(3) Select mode“F12”.
(4) Make sure duty ratio on radiator fan and electric
load is OFF.
Specified data: 25—40%
B2M0361
13. Pressure Sources Switching
Solenoid Valve (AT model)
A: REMOVAL AND INSTALLATION
1) Disconnect connector from pressure sources switching
solenoid valve.
2) Disconnect hoses from pressure sources switching
solenoid valve.
27
2-7SERVICE PROCEDURE
12. Idle Air Control Solenoid Valve - 13. Pressure Sources Switching Solenoid Valve (AT model)

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.
28
2-7SERVICE PROCEDURE
13. Pressure Sources Switching Solenoid Valve (AT model) - 15. Engine Control Module

G2M0434
2) Detach floor mat of front passenger seat.
3) Remove protect cover.
B2M0363
4) Release the lock of ECM connector and disconnect it.
5) Remove nuts which install ECM onto body.
6) Take out ECM.
B2M0364
7) Connect ECM connector and lock it.
8) Installation is in the reverse order of removal.
29
2-7SERVICE PROCEDURE
15. Engine Control Module

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
30
2-7SERVICE PROCEDURE
16. Main Relay

G6M0095
17. Fuel Pump 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 fuel pump relay from main relay and fuel pump
relay mounting bracket.
9) Disconnect connector from fuel pump relay.
G2M0438
10) Installation is in the reverse order of removal.


1Main relay


2Fuel pump relay
31
2-7SERVICE PROCEDURE
17. Fuel Pump Relay

FUEL SYSTEM2-8
Page
S SPECIFICATIONS AND SERVICE DATA....................................................2
1. Fuel System .............................................................................................2
C COMPONENT PARTS..................................................................................3
1. Fuel Tank ................................................................................................3
2. Fuel Line ..................................................................................................7
W SERVICE PROCEDURE...........................................................................10
1. Precautions ...........................................................................................10
2. On-Car Services ....................................................................................12
3. Fuel Tank ...............................................................................................13
4. Fuel Filler Pipe .......................................................................................16
5. Fuel Filter ..............................................................................................18
6. Fuel Pump ............................................................................................19
7. Fuel Meter Unit .....................................................................................20
8. Fuel Delivery, Return and Evaporation Lines ........................................22
9. Roll Over Valve ......................................................................................25
10. Fuel Sub Meter Unit (AWD model only) ................................................25
11. Fuel Cut Valve (AWD model only) .........................................................26
K DIAGNOSTICS...........................................................................................27
1. Fuel System ...........................................................................................27