fuel pressure SUBARU LEGACY 1997 Service Repair Manual

8
.
Electrical
Wiring
Harness
and
Ground
Point

Connector
Connecting
to

No
.
Pole
Color
Area
No
.
Name

R17
1
Black
A-3
Rear
defogger
(Power)

R18
2
Black
B-3
Rear
speaker
RH

R19
2B-3
High-mounted
stop
light

R20
2
Blue
B-2
Trunk
room
light

R21
2
Black
B-2
Rear
speaker
LH

R22
1
Brown
B-1
Rear
door
switch
LH

R23
3
B-2
Power
antenna

R24
6B-3
R60
Trunk
lid
cord(Without
security
system)

8
B-3
R60
Trunk
lid
cord
(With
security
system)

R25
2
Black
B-4
Rear
defogger
condenser

R26
4
B-4
Rear
combination
light
RH

R27
2
B-4
Trunk
room
light
switch

R28
4
B-3
Rear
combination
light
LH

R45
6
B-4
Trailer
connector
(SUS
model)

R47
3B-3Fueltank
pressure
sensor

R60
6B-4
R24
Rear
wiring
harness
(Without
security
system)

8B-4
R24
Rear
wiring
harness
(With
security
system)

R61
3B-4
Key
switch
(Security)

R62
4B-4
Rear
finisher
light
RH

R63
2B-3
License
plate
light

R64
4B-3
Rear
finisher
light
LH

R65
1
Black
A-2
Rear
defogger(Ground)

R66
2
Black
B-4
E
High-mounted
stop
light
(Rear
spoiler)

'
:
Non-colored

3

A

B

C

D

8
.
REAR
END
WIRING
HARNESS
AND
GROUND
POINT
OF
SEDAN

1
1
2

1

3

R65

1
R17
,

R19

4

\
R66

GD
A
~
~
R45
i

O
~~`
R18
''r
~
R25

R21
~
~O
\

R22
O
R20
R24
R47
~---

R23R2g
'
:
R60
R62

o

GB-9
0

~~,
.~I
~~I)~1

B6M0104B

2
R63R26
R64R27

R61~

~
GB-9

3
[D808]

B6M0823A

4

A

B

C

D

B2M1202A
B2M0425B
7. EGR Solenoid Valve
A: REMOVAL AND INSTALLATION
1. 2200 cc MODEL
1) Disconnect connector from EGR solenoid valve.
2) Disconnect vacuum hoses from EGR solenoid valve.
3) Remove bolt which installs EGR solenoid valve.
4) Take out EGR solenoid valve.
5) Installation is in the reverse order of removal.
Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
2. 2500 cc MODEL
1) Remove bolt which installs EGR solenoid valve onto
intake manifold.
2) Take out EGR solenoid valve.
3) Disconnect connector from EGR solenoid valve.
4) Disconnect vacuum hoses from EGR solenoid valve.
5) Remove EGR solenoid valve.
NOTE:
This figure shows the under side of intake manifold.
6) Installation is in the reverse order of removal.
Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
G6M0095
8. Fuel Temperature Sensor (2200 cc
AWD Model)
A: REMOVAL
1) Disconnect battery ground cable.
B2M0954A
2) Release fuel pressure.
3) Disconnect fuel delivery hose
1, return hose2and jet
pump hose
3.
9
2-1SERVICE PROCEDURE
7. EGR Solenoid Valve - 8. Fuel Temperature Sensor (2200 cc AWD Model)

B2M1202A
B2M0425B
7. EGR Solenoid Valve
A: REMOVAL AND INSTALLATION
1. 2200 cc MODEL
1) Disconnect connector from EGR solenoid valve.
2) Disconnect vacuum hoses from EGR solenoid valve.
3) Remove bolt which installs EGR solenoid valve.
4) Take out EGR solenoid valve.
5) Installation is in the reverse order of removal.
Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
2. 2500 cc MODEL
1) Remove bolt which installs EGR solenoid valve onto
intake manifold.
2) Take out EGR solenoid valve.
3) Disconnect connector from EGR solenoid valve.
4) Disconnect vacuum hoses from EGR solenoid valve.
5) Remove EGR solenoid valve.
NOTE:
This figure shows the under side of intake manifold.
6) Installation is in the reverse order of removal.
Tightening torque:
16±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
G6M0095
8. Fuel Temperature Sensor (2200 cc
AWD Model)
A: REMOVAL
1) Disconnect battery ground cable.
B2M0954A
2) Release fuel pressure.
3) Disconnect fuel delivery hose
1, return hose2and jet
pump hose
3.
9
2-1SERVICE PROCEDURE
7. EGR Solenoid Valve - 8. Fuel Temperature 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)

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)

B2M0960
3) Disconnect connector from fuel tank pressure sensor.
4) Remove bolts which install fuel tank pressure sensor
bracket on body.
B2M0961
5) Disconnect hose from fuel tank pressure sensor.
6) Remove fuel tank pressure sensor from bracket.
7) Installation is in the reverse order of removal.
G6M0095
10. Pressure Control Solenoid Valve
(2200 cc AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
2) Lift-up the vehicle.
B2M0962
3) Disconnect evaporation hoses from pressure control
valve.
4) Disconnect connector from pressure control valve.
B2M0963
5) Remove pressure control valve from bracket.
6) Installation is in the reverse order of removal.
12
2-1SERVICE PROCEDURE
9. Fuel Tank Pressure Sensor (2200 cc AWD Model) - 10. Pressure Control Solenoid Valve (2200 cc AWD Model)

B2M0960
3) Disconnect connector from fuel tank pressure sensor.
4) Remove bolts which install fuel tank pressure sensor
bracket on body.
B2M0961
5) Disconnect hose from fuel tank pressure sensor.
6) Remove fuel tank pressure sensor from bracket.
7) Installation is in the reverse order of removal.
G6M0095
10. Pressure Control Solenoid Valve
(2200 cc AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
2) Lift-up the vehicle.
B2M0962
3) Disconnect evaporation hoses from pressure control
valve.
4) Disconnect connector from pressure control valve.
B2M0963
5) Remove pressure control valve from bracket.
6) Installation is in the reverse order of removal.
12
2-1SERVICE PROCEDURE
9. Fuel Tank Pressure Sensor (2200 cc AWD Model) - 10. Pressure Control Solenoid Valve (2200 cc AWD Model)

G6M0095
12. Fuel Level Sensor (2200 cc AWD
Model)
A: REMOVAL
1) Disconnect battery ground cable.
B2M0954A
2) Release fuel pressure.
3) Disconnect fuel delivery hose
1, return hose2and jet
pump hose
3.
B2M0955
4) Remove nuts which install fuel pump assembly onto
fuel tank.
B2M0956
5) Take off fuel pump assembly from fuel tank.
H2M1459
6) Disconnect connector from fuel pump.
15
2-1SERVICE PROCEDURE
12. Fuel Level Sensor (2200 cc AWD Model)

3. RELATED PARTS
1) Install valve rocker assembly.

B2M0418B
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5±1 (0.5±0.1, 3.6±0.7)
T2: 12±1 (1.2±0.1, 8.7±0.7)
2) Install timing belt, camshaft sprockets and related parts.

6. Cylinder Head
A: REMOVAL
1. INTAKE MANIFOLD
1) Release fuel pressure.
2) Drain engine coolant.
3) Remove intake manifold.
4) Remove engine coolant pipe.
38
2-3SERVICE PROCEDURE
5. Camshaft - 6. Cylinder Head

3. RELATED PARTS
1) Install valve rocker assembly.

B2M0418B
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5±1 (0.5±0.1, 3.6±0.7)
T2: 12±1 (1.2±0.1, 8.7±0.7)
2) Install timing belt, camshaft sprockets and related parts.

6. Cylinder Head
A: REMOVAL
1. INTAKE MANIFOLD
1) Release fuel pressure.
2) Drain engine coolant.
3) Remove intake manifold.
4) Remove engine coolant pipe.
38
2-3SERVICE PROCEDURE
5. Camshaft - 6. Cylinder Head