1997 SUBARU LEGACY fuel cap

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 2Incorrect valve clearance
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

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 2Incorrect valve clearance
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)
78
2-3bDIAGNOSTICS
1. Engine Trouble in General

1Intake manifold gasket LH


2Intake manifold gasket RH


3Fuel injector pipe insulator


4Fuel injector pipe


5O-ring A


6O-ring B


7Fuel injector


8Insulator


9Fuel injector cap


10Plate


11Sealing


12Gasket


13Engine coolant hose B


14Air by-pass hose


15Idle air control solenoid valve


16Engine coolant hose A


17Nipple (AT model)


18Plug


19PCV valve


20Purge control solenoid valve


21Nipple


22BPT (Except 2200 cc MT model)


23BPT holder bracket (Except 2200 cc MT model)


24Back pressure hose (Except 2200 cc MT model)


25EGR vacuum hose A (Except 2200 cc MT model)

26EGR vacuum hose B (Except 2200 cc MT model)


27EGR valve (Except 2200 cc MT model)


28Gasket (Except 2200 cc MT model)


29EGR solenoid valve (Except 2200 cc MT model)


30EGR pipe (Except 2200 cc MT model)


31Pressure sensor


32Pressure sources switching solenoid valve


33Vacuum hose A


34Vacuum hose B


35Vacuum hose C


36Bracket (Except Canada spec. vehicles)


37Bracket (For Canada spec. vehicles)


38Intake manifold
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
T2: 4.9±0.5 (0.5±0.05, 3.6±0.4)
T3: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T4: 16±1.5 (1.6±0.15, 11.6±1.1)
T5: 19±1.5 (1.9±0.15, 13.7±1.1)
T6: 19±2 (1.9±0.2, 13.7±1.4)
T7: 23±3 (2.3±0.3, 16.6±2.2)
T8: 25±2 (2.5±0.2, 18.1±1.4)
T9: 34±2 (3.5±0.2, 25.3±1.4)
3
2-7COMPONENT PARTS
1. Intake Manifold

2. 2500 cc MODEL
B2M1198A

1Intake manifold gasket LH


2Intake manifold gasket RH


3Fuel injector pipe insulator


4Fuel injector pipe


5O-ring A


6O-ring B


7Fuel injector


8Insulator


9Fuel injector cap


10Plate


11Sealing


12Gasket


13Engine coolant hose B


14Air by-pass hose


15Idle air control solenoid valve


16Engine coolant hose A


17Nipple (AT model)


18Plug


19PCV valve

20Purge control solenoid valve


21Nipple


22BPT


23BPT holder bracket


24Back pressure hose


25EGR vacuum hose A


26EGR vacuum pipe


27EGR vacuum hose C


28EGR valve


29Gasket


30EGR vacuum hose B


31EGR solenoid valve


32EGR pipe


33Pressure sensor


34Pressure sources switching solenoid
valve


35Vacuum hose A


36Vacuum hose B


37Vacuum hose C

38Bracket
(Except Canada spec. vehicles)


39Bracket
(For Canada spec. vehicles)


40Collar


41Intake manifold
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
T2: 4.9±0.5 (0.5±0.05, 3.6±0.4)
T3: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T4: 16±1.5 (1.6±0.15, 11.6±1.1)
T5: 19±1.5 (1.9±0.15, 13.7±1.1)
T6: 19±2 (1.9±0.2, 13.7±1.4)
T7: 23±3 (2.3±0.3, 16.6±2.2)
T8: 25±2 (2.5±0.2, 18.1±1.4)
T9: 34±2 (3.5±0.2, 25.3±1.4)
4
2-7COMPONENT PARTS
1. Intake Manifold