SUBARU LEGACY 1996 Service Repair Manual

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.
27
2-8DIAGNOSTICS
1. Fuel System

1. Exhaust System
1. 2500 cc MODEL
B2M0311A

1Upper front exhaust pipe cover CTR


2Lower front exhaust pipe cover CTR


3Band RH


4Band LH


5Upper front exhaust pipe cover LH


6Lower front exhaust pipe cover LH


7Front exhaust pipe


8Lower front exhaust pipe cover RH


9Upper front exhaust pipe cover RH


10Gasket


11Spring


12Rear exhaust pipe

13Self-locking nut


14Gasket


15Muffler


16Cushion rubber


17Clamp


18Upper center exhaust pipe cover


19Center exhaust pipe


20Clamp B


21Upper rear catalytic converter cover


22Lower rear catalytic converter cover


23Gasket


24Front oxygen sensor

25Rear oxygen sensor


26Front catalytic converter


27Lower front catalytic converter cover


28Upper front catalytic converter cover
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 30±5 (3.1±0.5, 22.4±3.6)
T4: 35±5 (3.6±0.5, 26.0±3.6)
T5: 48±5 (4.9±0.5, 35.4±3.6)
2
2-9COMPONENT PARTS
1. Exhaust System

2. 2200 cc MODEL
B2M0723A

1Upper front exhaust pipe cover CTR


2Lower front exhaust pipe cover CTR


3Band RH


4Band LH


5Upper front exhaust pipe cover LH


6Lower front exhaust pipe cover LH


7Front exhaust pipe


8Lower front exhaust pipe cover RH


9Upper front exhaust pipe cover RH


10Gasket


11Spring


12Rear exhaust pipe


13Self-locking nut

14Gasket


15Muffler


16Cushion rubber


17Clamp


18Upper center exhaust pipe cover


19Center exhaust pipe


20Clamp B


21Upper rear catalytic converter cover


22Lower rear catalytic converter cover


23Gasket


24Front oxygen sensor


25Rear oxygen sensor (California 2200
cc model)

26Rear oxygen sensor (Except Califor-
nia 2200 cc model)


27Front catalytic converter


28Lower front catalytic converter cover


29Upper front catalytic converter cover
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 30±5 (3.1±0.5, 22.4±3.6)
T4: 35±5 (3.6±0.5, 26.0±3.6)
T5: 48±5 (4.9±0.5, 35.4±3.6)
3
2-9COMPONENT PARTS
1. Exhaust System

B2M0724
1. Front Exhaust Pipe and Center
Exhaust Pipe
A: REMOVAL
1) Disconnect front oxygen sensor connector.
B2M0725
2) Disconnect rear oxygen sensor connector. (California
2200 cc model)
B2M0312
3) Lift-up the vehicle.
4) Disconnect rear oxygen sensor connector. (Except Cali-
fornia 2200 cc model)
B2M0055
5) Separate center exhaust pipe from rear exhaust pipe.
B2M0054
6) Remove bolts which hold front exhaust pipe onto cylin-
der heads.
4
2-9SERVICE PROCEDURE
1. Front Exhaust Pipe and Center Exhaust Pipe

B2M0313
7) Remove front exhaust pipe and center exhaust pipe
from hanger bracket.
CAUTION:
Be careful not to pull down front exhaust pipe and
center exhaust pipe.
B2M0060
8) Separate front exhaust pipe from front catalytic con-
verter.
B2M0060
B: INSTALLATION
CAUTION:
Replace gaskets with new ones.
1) Install front catalytic converter to front exhaust pipe.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
B2M0313
2) Install front exhaust pipe and center exhaust pipe.
And temporarily tighten bolt which installs center exhaust
pipe to hanger bracket.
B2M0054
3) Tighten bolts which hold front exhaust pipe onto cylin-
der heads.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
5
2-9SERVICE PROCEDURE
1. Front Exhaust Pipe and Center Exhaust Pipe

B2M0055
4) Install center exhaust pipe to rear exhaust pipe.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B2M0313
5) Tighten bolt which holds center exhaust pipe to hanger
bracket.
Tightening torque:
35±5 N⋅m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
B2M0312
6) Connect rear oxygen sensor connector. (Except Califor-
nia 2200 cc model)
B2M0725
7) Lower the vehicle.
8) Connect rear oxygen sensor connector. (California
2200 cc model)
B2M0724
9) Connect front oxygen sensor connector.
6
2-9SERVICE PROCEDURE
1. Front Exhaust Pipe and Center Exhaust Pipe

B2M0055
2. Rear Exhaust Pipe
A: REMOVAL
1) Separate rear exhaust pipe from center exhaust pipe.
B2M0061
2) Separate rear exhaust pipe from muffler.
CAUTION:
Be careful not to pull down rear exhaust pipe.
G2M0315
3) Remove rear exhaust pipe bracket from rubber cushion.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to pipe bracket in advance.
SUBARU CRC (Part No. 004301003)
G2M0315
B: INSTALLATION
CAUTION:
Replace gaskets with new ones.
1) Install rear exhaust pipe bracket to rubber cushion.
NOTE:
To facilitate installation, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)
B2M0061
2) Install rear exhaust pipe to muffler.
Tightening torque:
48±5 N⋅m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)
7
2-9SERVICE PROCEDURE
2. Rear Exhaust Pipe

B2M0055
3) Install rear exhaust pipe to center exhaust pipe.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
8
2-9SERVICE PROCEDURE
2. Rear Exhaust Pipe

B2M0061
3. Muffler
A: REMOVAL AND INSTALLATION
1) Separate muffler from rear exhaust pipe.
B2M0062
2) Remove left and right rubber cushions.
CAUTION:
Be careful not to pull down muffler.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushions in advance.
SUBARU CRC (Part No. 004301003)
B2M0063
3) Remove front rubber cushion, and detach muffler
assembly.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)
B2M0061
4) Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
Tightening torque:
48±5 N⋅m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)
9
2-9SERVICE PROCEDURE
3. Muffler

1. Clutch System
A: SPECIFICATIONS
2200 cc
Clutch cover Diaphragm set load kg (lb) 450 (992)
Clutch discFacing material Woven
O.D. x I.D. x thickness mm (in) 225 x 150 x 3.5 (8.86 x 5.91 x 0.138)
Spline O.D. mm (in)
(No. of teeth)25.2 (0.992)
(24)
Clutch release lever ratio 3.0
Release bearing Grease-packed self-aligning
B: SERVICE DATA
2200 cc
Clutch pedal Full stroke mm (in) 140 — 150 (5.51 — 5.91)
Release
leverStroke mm (in) 24 — 26 (0.94 — 1.02)
Play at release lever center mm (in) 3 — 4 (0.12 — 0.16)
Clutch discDepth of rivet head mm (in)Standard 1.3 — 1.9 (0.051 — 0.075)
Limit of sinking 0.3 (0.012)
Limit for runout mm (in) 1.0 (0.039) at R = 107 (4.21)
2
2-10SPECIFICATIONS AND SERVICE DATA
1. Clutch System