1997 SUBARU LEGACY fuel pump

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)

B2M0955
4) Remove nuts which install fuel pump assembly onto
fuel tank.
B2M0956
5) Take off fuel pump assembly from fuel tank.
H2M1456
6) Remove two screws fixing terminals on fuel pump
assembly.
H2M1457
7) Disconnect connector from fuel pump.
H2M1458A
8) Remove fuel temperature sensor from fuel pump
assembly.
10
2-1SERVICE PROCEDURE
8. Fuel Temperature Sensor (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)

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.
LUBRICATION SYSTEM
22 3 3Incorrect oil pressure
2Loosened oil pump attaching bolts and defective
gasket
2Defective oil filter seal
2Defective crankshaft oil seal
32Defective rocker cover gasket
2Loosened oil drain plug or defective gasket
2Loosened oil pan fitting bolts or defective oil pan
COOLING SYSTEM
33221Overheating
333Over cooling
OTHERS
113 3Malfunction of Evaporative Emission Control
System
21Stuck or damaged throttle valve
322 2Accelerator cable out of adjustment
77
2-3DIAGNOSTICS
1. Engine Trouble in General