1996 SUBARU LEGACY fuel cap

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

1Clamp


2Fuel delivery hose A


3Fuel filter bracket


4Fuel filter holder


5Fuel filter cup


6Fuel filter


7Evaporation hose


8Clip


9Fuel delivery hose B


10Fuel return hose


11Roll over valve


12Roll over valve bracket


13Evaporation hose H


14Evaporation hose I


15Evaporation pipe B


16Canister hose A


17Canister hose B


18Canister holder


19Canister upper bracket


20Cushion rubber


21Canister lower bracket


22Canister


23Fuel pipe ASSY


24Fuel filler valve


25Fuel filler pipe


26Packing

27Ring A


28Ring B


29Fuel filler cap


30Fuel filler pipe protector


31Fuel tank pressure sensor


32Fuel tank pressure sensor hose A


33Fuel tank pressure sensor bracket


34Grommet


35Fuel tank pressure sensor hose B


36Air ventilator hose A


37Air ventilator pipe A


38Air ventilator hose B


39Air ventilator pipe B


40Air ventilator pipe protector


41Vent control solenoid valve


42Vent control solenoid valve hose


43Air filter hose A


44Air filter hose B


45Air filter


46Tapping screw
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 23±7 (2.3±0.7, 17±5.1)
T2: 25±7 (2.5±0.7, 18±5.1)
9
2-8COMPONENT PARTS
2. Fuel Line

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.
17
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
consecutive trips, MIL is turned off, but DTC remains at
on-board computer.

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

ContentConnector
No.Terminal
No.Signal (V)
Note
Ignition SW ON
(Engine OFF)Engine ON (Idling)
Knock
sensorSignal B84 3 2.8 2.8—
Shield B84 56 0 0—
AT/MT identification B84 81(AT) 5
(MT) 0(AT) 5
(MT) 0When measuring voltage between
ECM and body.
Back-up power supply B84 39 10—13 13—14 Ignition switch“OFF”:10—13
Control unit power supply B841
10—13 13—14—
2
Ignition
control#1,#2 B84 41 0 1—3.4—
#3,#4 B84 40 0 1—3.4—
Fuel
injector# 1 B84 96 10—13 1—14 Waveform
# 2 B84 70 10—13 1—14 Waveform
# 3 B84 44 10—13 1—14 Waveform
# 4 B84 16 10—13 1—14 Waveform
Idle air
control
solenoid
valveOPEN end B84 14—1—13 Waveform
CLOSE end B84 13—13—1 Waveform
Fuel pump relay control B84 32ON: 0.5, or less
OFF: 10—130.5, or less—
A/C relay control B84 31ON: 0.5, or less
OFF: 10—13ON: 0.5, or less
OFF: 13—14—
Radiator fan relay 1
controlB84 74ON: 0.5, or less
OFF: 10—13ON: 0.5, or less
OFF: 13—14—
Radiator fan relay 2
controlB84 73ON: 0.5, or less
OFF: 10—13ON: 0.5, or less
OFF: 13—14With A/C vehicles only
Self-shutoff control B84 63 10—13 13—14—
Malfunction indicator lamp B84 58——Light“ON”:1,orless
Light“OFF”:10—14
Engine speed output B84 64—0—13, or more Waveform
Torque control signal B84 79 5 5—
Mass air flow signal for
ATB84 47 0—0.3 0.8—1.2—
Purge control solenoid
valveB84 72ON: 1, or less
OFF: 10—13ON: 1, or less
OFF: 13—14—
Atmospheric pressure
sensorB84 26 3.9—4.1 2.0—2.3—
Pressure sources
switching solenoid valveB84 15ON: 1, or less
OFF: 10—13ON: 1, or less
OFF: 13—14—
EGR solenoid valve B84 71ON: 1, or less
OFF: 10—13ON: 1, or less
OFF: 13—14—
Front oxygen sensor
heater signalB84 38 0—1.0 0—1.0—
Rear oxygen sensor
heater signalB84 37 0—1.0 0—1.0—
Fuel temperature sensor B84 25 2.5—3.8 2.5—3.8
2200 cc AWD except Taiwan
model

Ambient temperature: 25°C
(77°F)
Fuel level sensor B84 27 0.12—4.75 0.12—4.75 2200 cc AWD except Taiwan model
Fuel tank
pressure
sensorSignal B84 4 2.3—2.7 2.3—2.7
2200 cc AWD except Taiwan
model

The value obtained after the fuel
filler cap was removed once and
recapped.
Power
supplyB84 21 5 5—
GND B84 20 0 0—
Fuel tank pressure control
solenoid valveB84 10ON: 1, or less
OFF: 10—13ON: 1, or less
OFF: 13—142200 cc AWD except Taiwan model
Vent control solenoid
valveB84 35ON: 1, or less
OFF: 10—13ON: 1, or less
OFF: 13—142200 cc AWD except Taiwan model
TCS signal B84 61 0—70—7 Waveform
71
2-7ON-BOARD DIAGNOSTICS II SYSTEM
5. Specified Data

OBD0727A
B2M0644A
8D1
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 step8D2.
OBD0123A
8D2CHECK POWER SUPPLY CIRCUIT FOR
IGNITION 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 and engine ground.
: Connector & terminal
(E12) No. 2 (+)—Engine ground ():
Is the voltage more than 10 V?
: Go to step8D3.
: Repair harness between ignition coil and ignition
switch connector.
OBD0124
8D3
CHECK IGNITION COIL.
1) Measure resistance between ignition coil terminals to
check primary coil.
: Terminals
No. 2—No. 1:
Is the resistance between 0.4 and 1.0Ω?
: Go to next.
: Replace ignition coil.
100
2-7ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure

H2M1365
AG: DTC P0440
—EVAPORATIVE EMISSION CONTROL
SYSTEM MALFUNCTION (EVAP)—
DTC DETECTING CONDITION:

Two consecutive trips with fault
TROUBLE SYMPTOM:

Gasoline smell
10AG1Check any other DTC (besides DTC P0440) on
display.
10AG2Check fuel filler cap and fuel filler pipe.
10AG3Check vent control solenoid valve.
10AG4Check purge control solenoid valve.
10AG5Check pressure control solenoid valve.
10AG6Check evaporative emission control system
line.
CAUTION:
After repair or replacement of faulty parts, conduct
CLEAR MEMORY and INSPECTION MODES.






236
2-7ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code