1999 SUBARU LEGACY fuel pump

8. Fuel Temperature Sensor
A: REMOVAL
1) Release fuel pressure.
2) Remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
B2M1723
4) Disconnect fuel delivery hose (A), return hose
(B) and jet pump hose (C).
B2M0954E
5) Remove nuts which install fuel pump assembly
onto fuel tank.
B2M0955
6) Take off fuel pump assembly from fuel tank.
B2M0956
7) Disconnect connector from fuel pump bracket.
S2M0145
8) Remove main fuel level sensor from fuel pump
assembly.
NOTE:
Fuel temperature sensor is a unit with fuel pump.
If replacing it, replace as a fuel pump.
S2M0855
11
[W8A0]2-1SERVICE PROCEDURE
8. Fuel Temperature Sensor

4) Connect connector to vent control solenoid
valve.
B2M0964
5) Connect two hoses to air filter.
B2M1888A
6) Install canister.
B2M1780
7) Lower the vehicle.
8) Connect battery ground cable.
B2M1723
12. Main Fuel Level Sensor
A: REMOVAL
1) Release fuel pressure.
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
B2M1723
4) Disconnect fuel delivery hose (A), return hose
(B) and jet pump hose (C).
B2M0954E
17
[W12A0]2-1SERVICE PROCEDURE
12. Main Fuel Level Sensor

4) Connect connector to vent control solenoid
valve.
B2M0964
5) Connect two hoses to air filter.
B2M1888A
6) Install canister.
B2M1780
7) Lower the vehicle.
8) Connect battery ground cable.
B2M1723
12. Main Fuel Level Sensor
A: REMOVAL
1) Release fuel pressure.
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
B2M1723
4) Disconnect fuel delivery hose (A), return hose
(B) and jet pump hose (C).
B2M0954E
17
[W12A0]2-1SERVICE PROCEDURE
12. Main Fuel Level Sensor

5) Remove nuts which install fuel pump assembly
onto fuel tank.
B2M0955
6) Take off fuel pump assembly from fuel tank.
B2M0956
7) Disconnect connector from fuel pump bracket.
S2M0145
8) Remove bolt which installs fuel level sensor on
mounting bracket.
S2M0855
B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts,
to prevent 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 following:
(1) Install the fuel level sensor onto the mounting
bracket.
S2M0855
(2) Always use new gaskets.
(3) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(4) Tighten nuts in alphabetical sequence shown
in figure to specified torque
Tightening torque:
4.4
±1.5 N´m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
B2M0955C
18
2-1[W12B0]SERVICE PROCEDURE
12. Main Fuel Level Sensor

14. Sub Fuel Level Sensor
A: REMOVAL AND INSTALLATION
1) Release fuel pressure.
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
B2M1723
4) Remove service hole cover.
G2M0863
5) Disconnect connector from fuel sub meter, and
disconnect jet pump hose.
S2M0151
6) Remove bolts which install sub fuel level sensor
on fuel tank.
S2M0152
7) Remove sub fuel level sensor.
S2M0153
8) Installation is in the reverse order of removal.
Tightening torque:
T: 4.4
±1.5 N´m (0.45±0.15 kg-m, 3.3±1.1
ft-lb)
S2M0152A
20
2-1[W14A0]SERVICE PROCEDURE
14. Sub Fuel Level Sensor

1. Engine Trouble in General
NOTE:
ªRANKº shown in the chart refer to the possibility of reason for the trouble in order (ªVery oftenº to ªRarelyº)
A Ð Very often
B Ð Sometimes
C Ð Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn.IStarterIDefective battery-to-starter harness B
IDefective starter switch C
IDefective inhibitor switch or neutral switch C
IDefective starter B
IBatteryIPoor terminal connecton A
IRun-down battrey A
IDefective charging system B
IFrictionISeizure of crankshaft and connecting rod bearing C
ISeized camshaft C
ISeized or stuck piston and cylinder C
2) Initial combustion does
not occur.IStarterIDefective starter C
IFuel injection system A
IFuel lineIDefective fuel pump and relay A
ILack of or insufficient fuel B
IBeltIDefective B
IDefective timing B
ICompressionIIncorrect valve clearance C
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating C
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing B
IImproper engine oil (low viscosity) B
3) Initial combustion occur.IFuel injection system A
IIntake systemIDefective intake manifold gasket B
IDefective throttle body gasket B
IFuel lineIDefective fuel pump and relay C
IClogged fuel line C
ILack of or insufficient fuel B
IBeltIDefective B
IDefective timing B
ICompressionIIncorrect valve clearance C
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating C
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing B
IImproper engine oil (low viscosity) B
73
[K100]2-3aDIAGNOSTICS
1. Engine Trouble in General

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
4) Engine stalls after initial
combustion.Fuel injection system A
IIntake systemILoosened or cracked intake uct B
ILoosened or cracked PCV hose C
ILoosened or cracked vacuum hose C
IDefective intake manifold gasket B
IDefective throttle body gasket B
IDirty air cleaner element C
IFuel lineIClogged fuel line C
ILack of or insufficient fuel B
IBeltIDefective B
IDefective timing B
ICompressionIIncorrect valve clearance C
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating C
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing B
IImproper engine oil (low viscosity) B
2. Rough idle and engine stall Fuel injection system A
IIntake systemILoosened or cracked intake duct A
ILoosened or cracked PCV hose A
ILoosened or cracked vacuum hose A
IDefective intake manifold gasket B
IDefective throttle body gasket B
IDefective PCV valve C
ILoosened oil filter cap B
IDirty air cleaner element C
IFuel lineIDefective fuel pump and relay C
IClogged fuel line C
ILack of or insufficient fuel B
IBeltIDefective timing C
ICompressionIIncorrect valve clearance B
ILoosened spark plugs or defective gasket B
ILoosened cylinder head bolts or defective gasket B
IImproper valve seating B
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston B
IIncorrect valve timing A
IImproper engine oil (low viscosity) B
ILubrication systemIIncorrect oil pressure B
IDefective rocker cover gasket C
ICooling systemIOverheating C
IOthersIMalfunction of evaporative emission control system A
IStuck or damaged throttle valve B
IAccelerator cable out of adjustment C
74
2-3a[K100]DIAGNOSTICS
1. Engine Trouble in General

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
3. Low output, hesitation and
poor accelerationIFuel injection system A
IIntake systemILoosened or cracked intake duct A
ILoosened or cracked PCV hose A
ILoosened or cracked vacuum hose B
IDefective intake manifold gasket B
IDefective throttle body gasket B
IDefective PCV valve B
ILoosened oil filter cap B
IDirty air cleaner element A
IFuel lineIDefective fuel pump and relay B
IClogged fuel line B
ILack of or insufficient fuel C
IBeltIDefective timing B
ICompressionIIncorrect valve clearance B
ILoosened spark plugs or defective gasket B
ILoosened cylinder head bolts or defective gasket B
IImproper valve seating B
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing A
IImproper engine oil (low viscosity) B
ILubrication systemIIncorrect oil pressure B
ICooling systemIOverheating C
IOver cooling C
IOthersIMalfunction of evaporative emission control system A
4. SurgingIFuel injection system A
IIntake systemILoosened or cracked intake duct A
ILoosened or cracked PCV hose A
ILoosened or cracked vacuum hose A
IDefective intake manifold gasket B
IDefective throttle body gasket B
IDefective PCV valve B
ILoosened oil filter cap B
IDirty air cleaner element B
IFuel lineIDefective fuel pump and relay B
IClogged fuel line B
ILack of or insufficient fuel C
IBeltIDefective timing B
ICompressionIIncorrect valve clearance B
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating C
IDefective valve stem C
IWorn or broken valve spring C
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing A
IImproper engine oil (low viscosity) B
ICooling systemIOverheating B
IOthersIMalfunction of evaporative emission control system C
75
[K100]2-3aDIAGNOSTICS
1. Engine Trouble in General