SUBARU LEGACY 1999 Service Repair Manual

4) Start the engine.
5) Measure fuel pressure while disconnecting
pressure regulator vacuum hose from collector
chamber.
Fuel pressure:
284 Ð 314 kPa (2.9 Ð 3.2 kg/cm2,41Ð
46 psi)
G2M0348
6) After connecting pressure regulator vacuum
hose, measure fuel pressure.
Fuel pressure:
177 Ð 206 kPa (1.8 Ð 2.1 kg/cm2,26Ð
30 psi)
G2M0348
2. Fuel Tank
A: REMOVAL
1) Release fuel pressure.
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
B2M1723
4) Drain fuel from fuel tank.
G2M0345
5) Remove rear seat cushion. (Sedan model)

B2M1736
9
[W2A0]2-8SERVICE PROCEDURE
2. Fuel Tank

6) Move rear seat cushion forward. (Wagon
model)
B2M1737
7) Disconnect connector of fuel tank cord from
rear harness.
B2M1738
8) Push grommet which holds fuel tank cord on
floor panel into under the body.
B2M1739A
9) Lift-up the vehicle.
10) Remove rear exhaust pipe.
(1) Separate rear exhaust pipe from center
exhaust pipe.
(2) Separate rear exhaust pipe from muffler.
(3) Remove bracket from rubber cushion, and
remove exhaust pipe.
NOTE:
To facilitate the removal of parts, apply a coat of
SUBARU CRC5-56 (Part No. 004301003). 2-9 [W3A0].>
Separate rear exhaust pipe from muffler.
S2M0158
11) Remove heat sealed cover.
S2M0166
12) Remove muffler assembly.

NOTE:
To facilitate the removal of parts, apply a coat of
SUBARU CRC5-56 (Part No. 004301003).
B2M0063
10
2-8[W2A0]SERVICE PROCEDURE
2. Fuel Tank

13) Loosen clamp, and disconnect evaporation
hose from canister.
B2M2381A
14) Loosen clamp, disconnect hose from joint
pipe.
B2M2382A
15) Disconnect connector from pressure control
solenoid valve.
B2M1742
16) Disconnect connector from drain valve.
B2M1743
17) Disconnect hoses from roll over valve.
S2M0167
18) Remove bolts which hold parking brake cable
holding bracket.
S2M0191
19) Remove rear differential assembly.
(1) Remove rear axle shafts from rear differen-
tial assembly.
(2) Remove rear differential front cover.
(3) Remove propeller shaft.
(4) Remove lower differential bracket.
(5) Set transmission jack under rear differential.
(6) Remove bolts which install rear differential
onto rear crossmember.

G3M0059
11
[W2A0]2-8SERVICE PROCEDURE
2. Fuel Tank

20) Remove rear crossmember.

G4M0545
21) Remove two evaporation hoses from holding
clip.
B2M1744A
22) Loosen clamp, and disconnect fuel filler hose.
B2M1745
23) Loosen clamp, and then disconnect fuel deliv-
ery hose (A).
24) Move clips, and disconnect fuel return hose
(B) and evaporation hose (C).
B2M0310B
25) While holding fuel tank, remove bolts from
bands and dismount fuel tank.
WARNING:
A helper is required to perform this work.
S2M0169A
B: INSTALLATION
1) While a helper holds fuel tank, push fuel tank
harness into access hole with grommet.
2) Set fuel tank, and temporary tighten bolts for
installing fuel tank bands.
S2M0169A
3) Connect fuel filler hose, and tighten clamp.
B2M1745
4) Install two evaporation hoses to holding clip.
12
2-8[W2B0]SERVICE PROCEDURE
2. Fuel Tank

B2M1744B
5) Install hose and hold down clips at positions
indicated in Figure.
Tightening torque:
1.0+0.5/þ0N´m (0.1+0.05/þ0kg-m, 0.7+0.4/þ0ft-lb)
Type A: When fitting length is specified.
Type B: When fitting length is not specified.

: 1.0 Ð 4.0 mm (0.039 Ð 0.157 in)
L: 20 Ð 25 mm (0.79 Ð 0.98 in)
B2M1194C
(1) Fitting
(2) Clamp
(3) Hose
Fuel return hose:
L = 20 Ð 25 mm (0.79 Ð 0.98 in)
Evaporation hose:
L = 15 Ð 20 mm (0.59 Ð 0.79 in)
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
6) Tighten band mounting bolts.
Tightening torque:
33
±10 N´m (3.4±1.0 kg-m, 25±7 ft-lb)
S2M0169A
7) Install rear crossmember. [W10C0].>
G4M0545
8) Install rear differential assembly. [W2F0].>
G3M0059
9) Connect connector to drain valve.
B2M1743
13
[W2B0]2-8SERVICE PROCEDURE
2. Fuel Tank

10) Connect connector to pressure control sole-
noid valve.
B2M1742
11) Connect hose to joint pipe, and tighten them
with clamp.
B2M2382A
12) Connect evaporation hose to canister, and
tighten them with clamp.
B2M2381A
13) Connect hoses to roll over valve.
S2M0167
14) Install muffler assembly.
B2M0063
15) Install heat sealed cover.
S2M0166
16) Install bolts which hold parking brake holding
bracket.
S2M0191
17) Install rear exhaust pipe. [W3B0].>
S2M0158
14
2-8[W2B0]SERVICE PROCEDURE
2. Fuel Tank

18) Lower the vehicle.
19) Connect connectors to fuel tank harness, and
plug access hole with grommet.
B2M1738
20) Install rear seat cushion. (Sedan model) to 5-3 [W2B1].>
B2M1736
21) Set rear seat cushion. (Wagon model)
B2M1737
22) Install fuel filler cap.
B2M1746
23) Install fuel pump, and connect connector and
fuel hoses.
B2M0047
24) Install fuel sub meter unit, and connect con-
nector and jet pump hose.
G2M0864
25) Connect battery ground cable.
B2M1723
15
[W2B0]2-8SERVICE PROCEDURE
2. Fuel Tank

3. Fuel Filler Pipe
A: REMOVAL
1) Release fuel pressure.
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
B2M1723
4) Drain fuel from fuel tank.
G2M0345
5) Remove screws which install fuel filler pipe on
filler lid open.
B2M1747
6) Remove wheel nuts of rear right side.
7) Lift-up the vehicle.
8) Remove rear right side wheel.
B2M1748
9) Remove bolts which install protector cover on
body.
B2M1749
10) While releasing the under side of protector
cover from hook, remove it.
B2M1750A
11) Disconnect evaporation hoses from pipes.
B2M1751
16
2-8[W3A0]SERVICE PROCEDURE
3. Fuel Filler Pipe

12) Remove bolts which hold fuel filler pipe
bracket.
B2M1752
13) Lift-up the vehicle more.
14) Remove two evaporation hoses from clip.
B2M1753
15) Disconnect evaporation hose from joint pipe.
B2M1754
16) Loosen clamp, and disconnect fuel filler hose
from fuel filler pipe.
B2M1745
17) Remove fuel filler pipe to under side of
vehicle.
B2M1756
B: INSTALLATION
1) Set fuel filler pipe from under side of vehicle,
and hold it on fuel filler flap open.
B2M1756
2) Connect fuel filler pipe into fuel filler hose.
B2M1757
17
[W3B0]2-8SERVICE PROCEDURE
3. Fuel Filler Pipe

3) Lower the vehicle.
4) Temporarily tighten screws which install fuel
filler pipe on filler lid open.
B2M1747
5) Tighten bolt which holds fuel filler pipe on body.
B2M1752
6) Connect evaporation hoses to pipes.
B2M1751
7) Lift-up the vehicle.
8) Tighten clamp bolt which holds fuel filler hose.
B2M1745
9) Install two evaporation hoses to clip.
B2M1753
10) Connect evaporation hose to joint pipe.
B2M1754
11) Lower the vehicle.
12) While holding the under side of protector
cover on bracket, install it.
B2M1750A
13) Tighten bolts which install protector cover on
body.
B2M1749
18
2-8[W3B0]SERVICE PROCEDURE
3. Fuel Filler Pipe