1999 SUBARU LEGACY fuel filter

(1) Clamp
(2) Fuel delivery hose A
(3) Fuel filter bracket
(4) Fuel filter holder
(5) Fuel filter cup
(6) Fuel filter
(7) Evaporation hose
(8) Clip
(9) Fuel delivery hose B
(10) Fuel return hose
(11) Roll over valve
(12) Roll over valve bracket
(13) Evaporation hose H
(14) Evaporation hose I
(15) Evaporation pipe B
(16) Evaporation hose J
(17) Evaporation hose K
(18) Joint pipe
(19) Canister hose A(20) Air filter hose A
(21) Drain valve hose
(22) Air filter hose B
(23) Air filter
(24) Drain valve
(25) Canister upper bracket
(26) Cushion rubber
(27) Canister lower bracket
(28) Canister holder
(29) Evaporation hose L
(30) Pressure control solenoid valve
(31) Canister hose B
(32) Pressure control solenoid valve
holder
(33) Canister
(34) Fuel pipe ASSY
(35) Fuel filler pipe
(36) Evaporation hose M
(37) Evaporation hose N(38) Shut valve
(39) Packing
(40) Ring A
(41) Ring B
(42) Fuel filler cap
(43) Fuel filler pipe protector
(44) Tapping screw
(45) Evaporation hose O
(46) Joint pipe
(47) Evaporation hose P
(48) Evaporation hose Q
(49) Evaporation pipe
Tightening torque: N´m (kg-m, ft-lb)
T1:
23±7 (2.3±0.7, 16.6±5.1)
T2:25±7 (2.5±0.7, 18.1±5.1)
6
2-8[C200]COMPONENT PARTS
2. Fuel Line

7) Take off fuel pump from fuel tank.
G2M0344
8) Drain fuel from fuel tank by using a hand pump.
WARNING:
Do not use a motor pump when draining fuel.
G2M0345
9) After draining fuel, reinstall fuel pump.
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)
G2M0346
10) After removing fuel sub meter unit, drain fuel
from there.
WARNING:
Do not use a motor pump when draining fuel.
B2M0049
D: MEASUREMENT OF FUEL
PRESSURE
WARNING:
Before removing fuel pressure gauge, release
fuel pressure.
NOTE:
If out of specification as measured at step 6),
check or replace pressure regulator and pressure
regulator vacuum hose.
1) Release fuel pressure.
2) Connect connector to fuel pump.
3) Disconnect fuel delivery hoses from fuel filter,
and connect fuel pressure gauge.
S2M0195
8
2-8[W1D0]SERVICE PROCEDURE
1. On-car Services

4. Fuel Filter
A: REMOVAL
1) Release fuel pressure.
2) Disconnect fuel delivery hoses from fuel filter.
S2M0195
3) Remove filter from holder.
B: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.
C: INSTALLATION
CAUTION:
IIf fuel hoses are damaged at the connecting
portion, replace it with a new one.
IIf clamps are badly damaged, replace with
new ones.
1) Installation is in the reverse order of removal.
2) Tighten hose clamp screws.
Tightening torque:
1.0+0.5/þ0N´m (0.1+0.05/þ0kg-m, 0.7+0.4/þ0ft-lb)
S2M0195
5. Fuel Pump
A: REMOVAL
1) Release fuel pressure.
2) Disconnect fuel delivery hose (A), return hose
(B) and jet pump hose (C) (AWD model only).
B2M0048B
3) Remove nuts which install fuel pump assembly
onto fuel tank.
G2M0343
4) Take off fuel pump from fuel tank.
G2M0344
21
[W5A0]2-8SERVICE PROCEDURE
5. Fuel Pump

4. Fuel Filter
A: REMOVAL
1) Release fuel pressure.
2) Disconnect fuel delivery hoses from fuel filter.
S2M0195
3) Remove filter from holder.
B: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.
C: INSTALLATION
CAUTION:
IIf fuel hoses are damaged at the connecting
portion, replace it with a new one.
IIf clamps are badly damaged, replace with
new ones.
1) Installation is in the reverse order of removal.
2) Tighten hose clamp screws.
Tightening torque:
1.0+0.5/þ0N´m (0.1+0.05/þ0kg-m, 0.7+0.4/þ0ft-lb)
S2M0195
5. Fuel Pump
A: REMOVAL
1) Release fuel pressure.
2) Disconnect fuel delivery hose (A), return hose
(B) and jet pump hose (C) (AWD model only).
B2M0048B
3) Remove nuts which install fuel pump assembly
onto fuel tank.
G2M0343
4) Take off fuel pump from fuel tank.
G2M0344
21
[W5A0]2-8SERVICE PROCEDURE
5. Fuel Pump

1. Fuel System Trouble in
General
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
qDefective terminal contact.Inspect connections, especially ground, and
tighten securely.
qTrouble in electromagnetic or electronic circuit parts. Replace fuel pump.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe.Clean, correct or replace air breather tube or
pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
5) Clogged or bent air breather tube or air vent tube.Clean, correct or replace air breather tube or air
vent tube.
3.Gasoline smell inside of compartment
1)Loose joints at air breather tube, air vent tube and fuel filler
pipe.Retightening.
2) Defective packing air tightness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4. Defective fuel meter indicator
1) Defective operation of fuel meter unit. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE:
When the vehicle is left unattended for an
extended period of time, water may accumulate in
the fuel tank.
1) To prevent water condensation:
ITop off the fuel tank or drain the fuel completely.
IDrain water condensation from the fuel filter.
2) Refilling the fuel tank:
Refill the fuel tank while there is still some fuel left
in the tank.
3) Protecting the fuel system against freezing and
water condensation:
ICold areas
In snow-covered areas, mountainous areas, skiing
areas, etc. where ambient temperatures drop
below 0ÉC (32ÉF) throughout the winter season,
use an anti-freeze solution in the cooling system.Refueling will also complement the effect of anti-
freeze solution each time the fuel level drops to
about one-half. After the winter season, drain water
which may have accumulated in the fuel filter and
fuel tank in the manner same as that described
under affected areas as below.
IAffected areas
When water condensation is notched in the fuel
filter, drain water from both the fuel filter and fuel
tank or use a water removing agent (or anti-freeze
solution) in the fuel tank.
4) Observe the instructions, notes, etc., indicated
on the label affixed to the anti-freeze solution
(water removing agent) container before use.
27
[K100]2-8DIAGNOSTICS
1. Fuel System Trouble in General