fuel cap SUBARU LEGACY 1996 Service Repair Manual

2-7
R1oBOO]
ON-BOARD
DIAGNOSTICS
II
SYSTEM

10
.
Diagnostics
Chart
with
Trouble
Code

OBD
(FBI)

P0440


H2M1365

BQ
:
DTC
P0440

-
EVAPORATIVE
EMISSION
CONTROL

SYSTEM
MALFUNCTION
(EVAP)
-

DTC
DETECTING
CONDITION
:

Two
consecutive
trips
with
fault

TROUBLE
SYMPTOM
:

Gasoline
smell

10BQ1
Check
any
other
OTC
(besides
OTC

P0440)
on
display
.

10B02
Check
fuel
filler
capand
fuel
filler
pipe
.

10B03Check
vent
control
solenoid
valve
.

10B04
Check
purge
control
solenoid
valve
.

10805
Check
pressure
control
solenoid
valve
.

10B06
Check
evaporative
emission
control

system
line
.

CAUTION
:

After
repair
or
replacement
of
faulty
parts,
conduct

CLEAR
MEMORY
and
INSPECTION
MODES
.

c
Ref
.
to
2-7
[T3D0]
and
[T3E0]
.*2
and
*4
>

18

ON-BOARD
DIAGNOSTICS
II
SYSTEM
ITyoso2i
2-7
10
.
DiagnosticsChart
with
Trouble
Code

WIRING
DIAGRAM
:

Main
relay
0

0

847

884

77
ECM

V

897
R69
S
.M
.J
.
~°c~

Vent
control
solenoid
valve
R68
R57R15

Pressure
control

862F45
SBF-2
O~C)-

B
~E

822
O
E4

Purge
control
solenoid
valve

--{~J

solenoid
valve
B84R68
R69
R57847
822
E4

1
U
49
10
11
1
1314
1
16
1
234
171
1
811
9
12012112212
1113
63
1
36
44
444

M56

5678
49
1
63
55116
68
/Ul
1
3
9101112
9
19
~Lltu
~
4L_L51bIJ~l
13141516

B2M1017

10BQ1
I
CHECK
ANY
OTHER
DTC
(BESIDES
DTC

P0440)
ON
DISPLAY
.

Is
there
any
other
DTC
on
display?

Inspect
the
relevant
DTC
using
"10
.
Diagnostics

Chart
with
Trouble
Code,
2-7
[T10A0]"*7
.

No
:
Go
to
step
101302
.

FILLER
PIPE
.

FILLER
CAPAND
FUEL

1)
Turn
ignition
switch
to
OFF
.

2)
Open
the
fuelflap
.

CHECK
:
Is
the
fuel
filler
cap
tightened
securely?

Tighten
fuel
filler
cap
securely
.

o
:
Go
to
next
CHECK
.

19

2-7
RyoBOS1
ON-BOARD
DIAGNOSTICS
II
SYSTEM

10
.
Diagnostics
Chart
with
Trouble
Code

J

-Test
mode
connector

B2M0432B

--

Vent
control
solenoid
valve

82M0925A

o

Pur
e
control
z----_
11
r
1
4
,1

~
~

solenoidvalve
L

OBD0025B
I

CHECK
:
Is
there
any
damage
to
the
seal
between
fuel

filler
cap
and
fuel
filler
pipe?

Repair
or
replace
fuel
filler
cap
and
fuel
filler
pipe
.

No
:
Go
to
step
111011303
.

CHECK
VENT
CONTROL
SOLENOID
VALVE
.

1)
Connect
test
mode
connector
.

2)
Turn
ignition
switch
to
ON
.

CHECK
:
Does
vent
control
solenoid
valve
produce

*

Go
to
step
10BQ4
.

No
:
Replace
vent
control
solenoid
valve
.

operating
sound?

NOTE
:

Vent
control
solenoid
valve
operation
check
can
also
be

executed
using
Subaru
Select
Monitor
(Function
mode
:

FD08)
.
For
the
procedure,
referto
"COMPULSORY
VALVE

OPERATION
CHECK
MODE"
2-7
[T3F0]
4
.

10B04
CHECK
I
VA
L
VE
.

PURGE
CONTROL
SOLENOID

Does
purge
control
solenoid
valve
produce

operating
sound?

NOTE
:

Purge
control
solenoid
valve
operation
check
can
also
be

executed
using
Subaru
Select
Monitor
(Function
mode
:

FD02)
.
For
the
procedure,
referto
"COMPULSORY
VALVE

OPERATION
CHECK
MODE"
2-7
[T3F0]*4
.

YES
:
Go
to
step
10BQ5
.

No
:
Replace
purge
control
solenoid
valve
.

20

2-7
[T10BS1)
ON-BOARD
DIAGNOSTICS
II
SYSTEM

10
.
Diagnostics
Chart
with
Trouble
Code

Data
link
connector
(for
Subaru
select
monitor
and
OBD-II
general
scan
tool)

)
'
~
'~A~
~
Data
link
connector
(for
Subaru
select
monitor
only)

82M1016A]

TNKP
(F43)

0
.
10
k
P
a
1
mmHg
H2M
1326

TNKP
(F43)

0
.
10
k
P
a
1
mmHg

H2M1326

CONNECT
SUBARU
SELECT
MONITOR
OR
10BS1
THE
OBD-II
GENERALSCAN
TOOL,
AND

READ
DATA
.

1)
Turn
ignition
switch
to
OFF
.

2)
Remove
fuel
filler
cap
.

3)
Install
fuel
filler
cap
.

4)
Connect
Subaru
Select
Monitor
or
the
OBD-II
general

scan
toolto
data
link
connector
.

5)
Turn
ignition
switchto
ON
and
Subaru
Select
Monitor

or
the
OBD-II
general
scan
tool
switch
to
ON
.

6)
Read
the
data
onSubaru
Select
Monitoror
the
OBD-II

general
scan
tool
.

o
Subaru
Select
Monitor
Designate
mode
using
functionkey
.

Function
mode
:
F43

o
F43
:
Display
shows
pressure
signal
value
sent
from
fuel

tank
pressure
sensor
.

CHECK
:
Is
the
value
less
than-2
.8
kPa
in
function

mode
F43?

,rES
:
Go
to
step
10BS2
.

No
:
Go
to
next
CHECK
CHECK
:
Is
the
value
more
than2
.8
kPa
in
function

mode
F43?

,rES
:
Go
to
step
10BS4
.

No
:
Repair
harness
and
connector
.

NOTE
:

In
this
case,
repair
the
following
:

9
Open
or
short
circuit
in
harness
between
fuel
tank
p

sure
sensor
and
ECM
connector

"
Poor
contact
in
coupling
connector
(B97)

"
Poor
contact
in
fuel
tank
pressure
sensor

"
Poor
contact
in
ECM
connector

"
OBD-II
general
scan
tool

For
detailed
operation
procedures,
referto
the
OB

General
Scan
Tool
Instruction
Manual
.

30

res-

D-II

ON-BOARD
DIAGNOSTICS
II
SYSTEM
[TloBSa1
2-7
10
.
DiagnosticsChart
with
Trouble
Code

TNKP
(F43)

0
.
10
k
P
a
1
mmHg

H2M1326

5)
Disconnect
connector
from
fuel
tank
pressure
sensor
.

6)
Remove
fuel
filler
cap
.

7)
Install
fuel
filler
cap
.

8)
Turn
ignition
switchto
ON
and
Subaru
Select
Monitor

or
theOBD-II
general
scan
tool
switch
to
ON
.

9)
Read
data
onSubaru
select
monitor
or
the
OBD-II
gen-

eral
scan
tool
.

e
Subaru
Select
Monitor

Designate
mode
using
function
key
.

Function
mode
:
F43

CHECK
:
Is
the
value
more
than2
.8
kPa
in
function

mode
F43?

,rES
:
Repair
short
circuit
in
harnessbetween
ECM
and

fuel
tank
pressure
sensor
connector
.

No
:
Replace
fuel
tankpressure
sensor
.

~
OBD-II
general
scan
tool

For
detailed
operation
procedures,
referto
the
OBD-II

General
Scan
Tool
Instruction
Manual
.

35

B2M0955A
B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent fuel from flowing out through fuel delivery and
return pipes. Close fuel filler cap after tightening nuts.
Installation is in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
G6M0095
9. Fuel Tank Pressure Sensor (2200 cc
AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
H2M1122B
2) Remove trims.

4 door model:
Remove right trunk side trim.
B2M0927A

Wagon model:
(1) Remove right rear quarter upper rear trim.
(2) Remove right strut cap.
(3) Remove right rear quarter pillar lower trim.
11
2-1SERVICE PROCEDURE
8. Fuel Temperature Sensor (2200 cc AWD Model) - 9. Fuel Tank Pressure Sensor (2200 cc AWD Model)

B2M0955A
B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent fuel from flowing out through fuel delivery and
return pipes. Close fuel filler cap after tightening nuts.
Installation is in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
G6M0095
9. Fuel Tank Pressure Sensor (2200 cc
AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
H2M1122B
2) Remove trims.

4 door model:
Remove right trunk side trim.
B2M0927A

Wagon model:
(1) Remove right rear quarter upper rear trim.
(2) Remove right strut cap.
(3) Remove right rear quarter pillar lower trim.
11
2-1SERVICE PROCEDURE
8. Fuel Temperature Sensor (2200 cc AWD Model) - 9. Fuel Tank Pressure Sensor (2200 cc AWD Model)

H2M1460
7) Remove two screws fixing bracket on fuel pump assem-
bly.
H2M1461A
8) Remove one screw fixing fuel level sensor on bracket.
9) Remove fuel level sensor from fuel pump assembly.
B2M0955A
B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent fuel from flowing out through fuel delivery and
return pipes. Close fuel filler cap after tightening nuts.
Installation is in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
B2M0968
13. Air Filter (2200 cc AWD Model)
A: REMOVAL AND INSTALLATION
1) Remove canister.
2) Remove two hoses from air filter.
3) Remove flange nut from bracket.
4) Installation is in the reverse order of removal.
16
2-1SERVICE PROCEDURE
12. Fuel Level Sensor (2200 cc AWD Model) - 13. Air Filter (2200 cc AWD Model)

H2M1460
7) Remove two screws fixing bracket on fuel pump assem-
bly.
H2M1461A
8) Remove one screw fixing fuel level sensor on bracket.
9) Remove fuel level sensor from fuel pump assembly.
B2M0955A
B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent fuel from flowing out through fuel delivery and
return pipes. Close fuel filler cap after tightening nuts.
Installation is in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
B2M0968
13. Air Filter (2200 cc AWD Model)
A: REMOVAL AND INSTALLATION
1) Remove canister.
2) Remove two hoses from air filter.
3) Remove flange nut from bracket.
4) Installation is in the reverse order of removal.
16
2-1SERVICE PROCEDURE
12. Fuel Level Sensor (2200 cc AWD Model) - 13. Air Filter (2200 cc AWD Model)

TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
INTAKE SYSTEM
2111 3Loosened or cracked intake air pipe
3111 3 1Loosened or cracked blow-by hose
31211 2Loosened or cracked vacuum hose
22222Defective intake manifold gasket
22222Defective throttle body gasket
322 2 2Defective PCV valve
222 323Loosened oil filler cap
3312 1Dirty air cleaner element
FUEL LINE
13 322Defective fuel pump and relay
33322Clogged fuel line
222233Lack of or insufficient fuel
BELT
222Defective
222322 22 2Defective timing
FRICTION
3Seizure of crankshaft and connecting rod bearing
3Seized camshaft
3Seized or stuck piston and cylinder
COMPRESSION
333222 23 2Defective hydraulic lash adjuster
333223 3 3Loosened spark plugs or defective gasket
333223 3 3Loosened cylinder head bolts or defective gasket
333223 2 2Improper valve seating
333333 3 13Defective valve stem
222223 3 3Worn or broken valve spring
333233 3 12Worn or stuck piston rings, cylinder and piston
222111 12 2Incorrect valve timing
222222Improper engine oil (low viscosity)
76
2-3DIAGNOSTICS
1. Engine Trouble in General