1995 SUBARU LEGACY fuel cap

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

1. Collector Chamber and Intake
Manifold
B2M0338A

1Intake manifold gasket RH


2Intake manifold gasket LH


3Fuel injector pipe insulator


4Fuel injector pipe


5O-ring A


6O-ring B


7Fuel injector


8Insulator


9Fuel injector cap


10Gasket


11Engine coolant hose B


12Air by-pass hose


13Idle air control solenoid valve


14Engine coolant hose A

15Nipple (AT model)


16Plug


17PCV valve


18Purge control solenoid valve


19Nipple


20BPT


21BPT holder bracket


22Back pressure hose


23EGR vacuum hose A


24EGR vacuum pipe


25EGR vacuum hose C


26EGR valve


27Gasket


28EGR vacuum hose B

29EGR solenoid valve


30EGR pipe


31Intake manifold
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
T2: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T3: 16±1.5 (1.6±0.15, 11.6±1.1)
T4: 19±1 (1.9±0.1, 13.7±0.7)
T5: 19±1.5 (1.9±0.15, 13.7±1.1)
T6: 23±3 (2.3±0.3, 16.6±2.2)
T7: 25±2 (2.5±0.2, 18.1±1.4)
T8: 34±2 (3.5±0.2, 25.3±1.4)
2
2-7COMPONENT PARTS
1. Collector Chamber and Intake Manifold

1. Fuel System
A: SPECIFICATIONS
Fuel tankCapacity 60
(15.9 US gal, 13.2 Imp gal)
Location Under rear seat
Fuel pumpType Impeller
Discharge pressure 250.1 kPa (2.55 kg/cm
2, 36.3 psi)
Discharge flowAWD: More than 80
(21.1 US gal, 17.6 Imp gal)/h
FWD: More than 65
(17.2 US gal, 14.3 Imp gal)/h
[12 V at 300 kPa (3.06 kg/cm
2, 43.5 psi)]
Fuel filterCartridge type
2
2-8SPECIFICATIONS AND SERVICE DATA
1. Fuel System

G2M0360
3) Remove right rear wheel.
4) Open fuel filler flap and remove filler cap.
5) Remove screws holding packing in place.
G2M0361
6) Lift-up the vehicle.
7) Remove fuel filler pipe protector.
G2M0353
8) Remove clip, and separate air vent hose from pipe.
9) Loosen clamp, and separate fuel filler hose from pipe.


1Fuel filler hose


2Air vent hose
10) Remove fuel filler pipe to under side of the vehicle.
G2M0364
B: INSTALLATION
1) Hold fuel filler flap open.
2) Set fuel saucer

1with rubber packing
3, and insert fuel
filler pipe into hole from the inner side of apron.
3) Align holes in fuel filler pipe neck and set cup

2, and
tighten screws.
NOTE:
If edges of rubber packing are folded toward the inside,
straighten it with a screwdriver.
G2M0353
4) Insert fuel filler hose approximately 25 to 30 mm (0.98
to 1.18 in) over the lower end of fuel filler pipe and tighten
clamp.


1Fuel filler hose


2Air vent hose
CAUTION:
Do not allow clips to touch air vent hose and rear sus-
pension crossmember.
13
2-8SERVICE PROCEDURE
4. Fuel Filler Pipe

1. Body Electrical
A: SPECIFICATIONS
BatteryReserve capacity 82 minutes (MT), 100 minutes (AT)
Cold cranking ampere 430 amperes (MT), 490 amperes (AT)
Fuse10 A, 15 A, 20 A
Combination
meterSpeedometer Electric pulse type
Tachometer Electric impulse type
Water temperature gauge Thermistor cross coil type
Fuel gauge Resistance cross coil type
Charge indicator light 12 V—1.4 W
Brake fluid level warning/parking brake indicator light 12 V—1.4 W
AT oil temperature warning light (AWD only) 12 V—1.4 W
A.B.S. warning light 12 V—1.4 W
CHECK ENGINE warning light
(Malfunction indicator lamp)12 V—1.4 W
Oil pressure warning light 12 V—1.4 W
AIRBAG system warning light 12 V—1.4 W
Low fuel warning light 12 V—3W
FWD indicator light 12 V—1.4 W
TCS warning light 12 V—1.4 W
TCS indicator light 12 V—1.4 W
Turn signal indicator light 12 V—1.4 W (2 pieces)
Seat belt warning light 12 V—1.4 W
Door open warning light 12 V—1.4 W
Headlight beam indicator light 12 V—1.4 W
Meter illumination light12 V—3 W (2 pieces)
12 V—3.4 W (4 pieces)
Headlight 12 V—60/55 W (Halogen)
Front clearance light 12 V—5W
Turn signal lightFront 12 V—21 W
Rear 12 V—21 W
Tail/Stop light 12 V—5/21 W
Back-up light 12 V—21 W
High-mount stop light12 V—18 W (SEDAN), 12 V—13 W
(WAGON)
License plate light 12 V—5W
Room light 12 V—8W
Trunk room light (SEDAN) 12 V—5W
Luggage room light (WAGON) 12 V—5W
Spot light 12 V—8 W (2 pieces)
Glove box light 12 V—3.4 W
Ash tray illumination light 12 V—1.7 W
Selector lever illumination light (AT model) 12 V—1.7 W
2
6-2SPECIFICATIONS
1. Body Electrical

1. General
1. GENERAL DESCRIPTION

The on-board diagnostics (OBD) system detects and
indicates a fault in various inputs and outputs of the com-
plex electronic control. CHECK ENGINE malfunction indi-
cator lamp (MIL) in the combination meter indicates occur-
rence of a fault or trouble.

Further, against such a failure or sensors as may disable
the drive, the fail-safe function is provided to ensure the
minimal driveability.

The OBD system incorporated with the vehicles within
this engine family complies with Section 1968.1, California
Code of Regulations (OBD-II regulation). The OBD system
monitors the components and the system malfunction
listed in Engine Section which affects on emissions.

When the system decides that a malfunction occurs, MIL
illuminates. At the same time of the MIL illumination or
blinking, a diagnostic trouble code (DTC) and a freeze
frame engine conditions are stored into on-board com-
puter.

The OBD system stores freeze frame engine condition
data (engine load, engine coolant temperature, fuel trim,
engine speed and vehicle speed, etc.) into on-board com-
puter when it detects a malfunction first.

If the OBD system detects the various malfunctions
including the fault of fuel trim or misfire, the OBD system
first stores freeze frame engine conditions about the fuel
trim or misfire.

When the malfunction does not occur again for three
trips, MIL is turned off, but DTC remains at on-board com-
puter.

The OBD-II system is capable of communication with a
general scan tool (OBD-II general scan tool) formed by ISO
9141 CARB.

The OBD-II diagnostics procedure is different from the
usual diagnostics procedure. When troubleshooting OBD-II
vehicles, connect Subaru select monitor or the OBD-II gen-
eral scan tool to the vehicle.
A: ENGINE
1. ENGINE AND EMISSION CONTROL SYSTEM

The Multipoint Fuel Injection (MFI) system is a system
that supplies the optimum air-fuel mixture to the engine for
all the various operating conditions through the use of the
latest electronic technology.
With this system fuel, which is pressurized at a constant
pressure, is injected into the intake air passage of the cyl-
inder head. The injection quantity of fuel is controlled by an
intermittent injection system where the electro-magnetic
injection valve (fuel injector) opens only for a short period
of time, depending on the quantity of air required for one
cycle of operation. In actual operation, the injection quan-
2
2-7ON-BOARD DIAGNOSTICS II SYSTEM
1. General

OBD0727
1
CHECK IGNITION SYSTEM FOR SPARKS.
1) Remove plug cord cap from each spark plug.
2) Install new spark plug on plug cord cap.
CAUTION:
Do not remove spark plug from engine.
3) Contact spark plug’s thread portion on engine.
4) While opening throttle valve fully, crank engine to check
that spark occurs at each cylinder.
: Does spark occur at each cylinder?
: Check fuel pump system.
: Go to step 2.
OBD0123A
2CHECK POWER SUPPLY CIRCUIT FOR IGNI-
TION COIL.
1) Turn ignition switch to OFF.
2) Disconnect connector from ignition coil.
3) Turn ignition switch to ON.
4) Measure power supply voltage between ignition coil
connector terminal and body.
: Connector & terminal
(E12) No. 2—Body /10 V, or more
: Go to step 3.
: Repair harness between ignition coil and ignition
switch connector.
OBD0124
3
CHECK IGNITION COIL.
1) Measure resistance between ignition coil terminals to
check primary coil.
: Terminals
No. 2—No. 1/0.7±0.3Ω
No. 2—No. 3/0.7±0.3Ω
: Replace ignition coil.
: Go to next step.
11 7
2-7ON-BOARD DIAGNOSTICS II SYSTEM
9. Diagnostics for Engine Starting Failure