FUEL SYSTEM SUBARU. 1992 SERVICE MANUAL M_ MECHANISM AND FUNCTION 1, Fuel Lines... 2. Fuel Tank 3. Fuel Pump 4, Jet Pump (4WD model only) 5. Fuel Filter. ‘S_ SPECIFICATIONS AND SERVICE DATA © COMPONENT PARTS 1. Fuel Tank 2, Fuel Lines W SERVICE PROCEDURE .. Precautions Fuel Tank Fuel Filler Fuel Filter Fuel Pump Fuel Meter Unit Fuel Meter Unit (4WD model only Fuel Separator {4WD model only) . Fuel Delivery, Return and Evaporation Lines 10. Two-way Valve T TROUBLESHOOTING .. PONOTEwVe2-8 [M101] FUEL SYSTEM M MECHANISM AND FUNCTION 1. Fuel Lines ‘The return line returns excess fuel to the fuel tank vig the pressure regulator to maintain a constant level of fuel pressure. ‘The evaporation line consists of a two-way valve, canister, check valve and solenoid valve. On 4WD models, a fuel separator is additionally provided. ‘The fuel lines consist of a delivery line, return line, and ‘an evaporation line. The delivery line supplies fuel from the fuel tank to the intake manifold and consists of a pump filter, fuel pump and fuel filter. On 4WD models, a suction jet pump is used to prevent fuel from remain- ing in one of the two tank chambers, 1. MPFL selenide | Airclaener “Trot body Inte mann Pain ly tome a 7 Foal ctor + o Fut tery toe = SO oa rat tin Fu tr ‘invent oe se Po ar cap Tank wapeation tre m ll: Bey ve Fun pce canine Fontan Fun pum Fier aces Fig. 1 FWD model ( 7FUEL SYSTEM pu solenoid vive L Air cleaner Trotte boy ‘Sa mn = meme hr mite a G latte = Istmnwnee =P Eres rare fate tee i cai | = Sf — te pump ual pipe ‘Canisr Fual Tank te pone te = Fig. 2 4WD model = = —> a = ie Fuel delivery line Ls at Fig. 3 Turbo model(w102] FUEL SYSTEM . SPF Fost damper Air laser Pressure regulator: ——_ ‘Solenoid valve. ae = Injector body Page tine ~ | \C test ‘Tank evaporation line Ai valve Canitr = Ateveotpine Fuel otra ne Fuel fier es j Fuel dlvery tine Fon er Fust tank: paleee. woes Fig. 4 FWD model Fuel damper Ale sleanee j=see Pressure regulator i sotenold valve Ful neetor as Injector booty Pure tne eee ~ Iotoke manifold way vive Tank weportio ine { == Ale vent pipe: Fuel revi ine Lay = Foal filer eae w Fual cattery he ua iter = canter Fuel tank Fuel pipe aia Jet pump Fuel pum Fier same Fig. § 4WD modela te system ost 2g > 3. CARBURETOR ‘Soleneld valve ‘check valve Fr evaporation Air cleaner ine Purge fine estes |_— caturetor Water temperature vaive Carat fost N. naka ant | way valve ;— <= » us tw lr vent pips Pus! fillar cop Ful return 3 daivery tine a eH ain Fig. 6 FWD model cal es Air cleaner ee ila Purge hi” ann — | Water temperature valve: 5 Carter tot Nata mont Seo {evant evaporation tne t Faleurnioe Alrvant pipe on ‘Fuel filler cap aioe sa eae ice aig a Fig. 7 4WD model 92-8 _[M200} FUEL SYSTEM 28 2 Eee 2. Fuel Tank The fuel tank is located under the rear seat and secured with holddown bands, On 4WD models, the fuel tank utilizes a dented design to prevent interference with the differen The \k (for the 4WD model) has two chambers, and is provided with a suction jet pump which transfers fuel from one chamber to another. These fuel chambers, each have a built-in fuel meter unit. ‘One fuel drain plug is used on the FWD mode! and two drain plugs are utilized on the 4WD model. FWD model Fig. & “4WD model FFusl pump and fusl meter \.FUEL SYSTEM ) 3. Fuel Pump A. CONSTRUCTION The fuel pump is an impeller type. It is built into the fuel tank together with the fuel meter unit to provide quiet operation, The fuel pump consists of a motor, impeller, pump casing, pump cover, relief valve, check valve and purnp filter ust meter unit Float 52.400 Fig. 9 B, OPERATION ) 1) won the engine ster, fuel pump relay activates, This operates the motor to rotate the impeller. 2) Fuel entering a vane groove of the impeller flows along the fuel passage and into the next vane groove by centrifugal force. During the time fuel flows from one groove to the next, a pressure differential is produced by friction of the flow. 3) Thus, fuel pressure increases while the action is described in step 2) above is repeate charged from the pump casing. Fuel under pressur then passes through the clesrance between the arma. ture and the magnet and is discharged from the fuel pump. 4) As fuel discharge pressure reaches the specified value, the relief valve opens. This discharges fuel under pressure into the fuel tank. Fuel from the fuel tank then returns to the suction port and passes through the fuel pump. This action of fuel flow is repeated. In this manner, the relief valve prevents an abnormal increase in fuel pressure '5) When the engine and fuel pump stop, spring force acts on the check valve to close the discharge port so that fuel pressure remains in the fuel delivery li2-8 [Moo] FUEL SYSTEM 4, Jet Pump (4WD model only) This negative pressure allows fuel to be sucked up. The jot pump utilizes the velocity of fuel returning from the engine to produce negative pr inside the jet pump. Be2e7 Fig. 10FUEL SYSTEM [N00] 2-8 : ilte! With thie design, fuel flows from the perimeter of the 5. Fuel Filter f element to the interior of the fiter. ‘The fue fiter utilizes a pressure-withstanding, cartridge design. t hes a filter element built into the metal case. ™ d e220 Fig. 11 MPFI (Non-Turbo & Turbo) and SPFI model2-8 [M500] FUEL SYSTEM out Fig. 12 Carburetor modelFUEL SYSTEM S SPECIFICATIONS AND SERVICE DATA A: SPECIFICATIONS 1. MPFI Non-TURBO AND SPFI MODELS [Capacky [20 ¢(16.0 US gat, 19.2 Imp gal) ocstion [Under rear seat Type Impelt Discharge pressure [260.1 kPa (2.65 ko/omr, 90.3 psi), Discharge flow ‘More than 80 € (21.4 US gal, 17.6 imp galvh [12 V at 250.1 kPa (2.55 kg/em 26.3 pei) Cartridge type 2, TURBO MODEL opacity 7.0 €(1.1 US qf, 0.9 Imp at) oe epost 60 (16.0 US ge, 132 imo ge ta Location ner east Type Impeller ig eet Discharge pressure 200. a (9.05 lon, 438 pod ‘More than 160 ¢ (39.6 US gal, 33.0 Imp gall/H min. Discharge flow (12 V at 209.1 kPa (3.05 kg/om®, 43.4 pail} {Capacity 3. CARBURETOR MODEL Capacity 60 (15.9 US gat, 13.2 Imp gal) = ane = a Fuel pump Discharge pressure 17.7 - 23.6 kPa (0.18 - 0.24 kg/cm’, 2.6 - 3.4 psi) = Hepa oe omen ws wa eae Fuel separator Capacity " 1.0 (1.4 US at, 0.9 Imp at),2-8 [C1A0] FUEL SYSTEM. C COMPONENT PARTS 1. Fuel Tank A: FWD MODEL Tightening torque: Nem (kg-m, ft-lb) 1 06, 22 — 4.3) 2 Fig. 13FUEL SYSTEM B: 4WD MODEL Fig. 14 Tightening torque: Nom (kg-m, ft-lb) TH 3-6 (0. T2: 23 — 42 (2.3, [C180] 2-8 Fuel pump ASSY Fuel meter unit, Fuel pump Ful fier Gasket Filler hose Airvent hoes Tanke Bend Protector Bracket Cover “Tworway val Hose (evaporation) Hose (delivery) Hi Pipe (evaporation) Pipe (aub dalivery) Hose (ub delivery) Hose (return) Hose (delivery) Hose (sub delivery) ‘Hose (evaporation) Hose (Air breather! Hose (Air breather] Pipe (evaporation) Packing Filter e2182-8 [C2A1] FUEL SYSTEM 2. Fuel Lines ‘A: FWD MODEL 1. MPF AND SPFI MODELS 2 How 3 Hose 4 How 5 How How (delivery) 7 Foal filter 8 Hote (aetivery) © Pipe (evsporation) 10 ipe (return) 11. Pipe (delivery) 12, Howe (alr vant) 13 Pipe (air vent) Fig. 16 17 Packing 18 Filler pipeFUEL SYSTEM {c2a2} 2-8 2. CARBURETOR MODEL 40 Pipe (return) 11 Pipe delivery) = 12. Hose (alr vent) 13 Pipe lair vent) 14 Protector pea acs 18 Filler cop ig. 16. Ring ASSY 17 Packing 18 Fillerpipe2-8 [C280] FUEL SYSTEM B: 4WD MODEL 1. MPFI AND SPFI MODELS 32 Aux contol vale Z lary purge contr va 7 Fig. 17FUEL SYSTEM 2, CARBURETOR MODEL (c2B2] 2-8 1 Canister 2 How 2 Hove 4 Howe 5 How 6 Hove (daivery) 7 aa fier 8 Hore (daivery) Pipe (evoportion) 10. Pie (return) 1 Pipe (dover) 42 Howe fir vont) 19, Plo (ir vere) 14 Protector 18 Filler cap D $6 Ring ASSY 17 Packing 48 Filer pipe BD 0 wrist 20. Seperatar 24 Howe A 28 Bracket 26 Separator 27 Bracket2-8 [W100] W_ SERVICE PROCEDURE 1. Precautions ‘8, Before starting the job, be sure to carry out the following. 1) Place “No fire” signs near the working area, 2) Disconnect ground cable from battery. b. Be careful not to spill fuel on the floor. 4. RELEASING OF FUEL PRESSURE 1) Fold down the rear seat back, and turn up the floor mat. 2) Remove access hole lid. 3) Disconnect fuel pump connector. 5) After the engine has stalled, crank it for five more seconds. 6) Turn ignition switch “OFF”. FUEL SYSTEM 2. Fuel Tank REMOVAL 1) Release fuel pressure. Refer to Section 1. [W101] 2) Drain fuel from tank, 3) Remove muffler, rear suspension crossmember and rear differential ASSY. (4WD model only) 4) Remove fuel filler cap and drain fuel from fuel tank. 5) Remove clamp and fuel filler pipe. 6) Remove clamp and disconnect air vent hose from fuel filler pipe. Fig. 21FUEL SYSTEM [W2A0} 2-8 7) Loosen clips and disconnect air breather hoses and evaporation hose from pipes. (4WD model only) 9) While holding fuel tank, remove bolts from bands and dismount fuel tank. Fig. 22 8) Loosen clips and clamp, and disconnect delivery hose, return hose and evaporation hose from pipes. Fig. 24 ‘Two men are required to perform step 7) above. 10) Disconnect hamess connector from fuel pump ASSY. ‘On 4WD models, also disconnect harness connector from fuel meter unit. Have a helper support fuel tank, when disconnecting harness. Fig, 238_1W280] FUEL SYSTEM B: INSTALLATION Installation is in the reverse order of removal proce- dures. Observe the following: 1) When installing fuel tank, have @ helper hold fuel tank while connecting hoses end harness connector. 2) Before tightening band mounting bolts, make sure hoses, harnesses, ete. are not caught between fuel tank and car body. 3) Install hose and tube holddown clips at positions indicated in the figure. ip Ploe ta’ ual etura ine: ‘L= 20~ 28 mm (0.70 — 0:98 in) Evaporation ine: E= 18 ~20 mm (0.59 — 0.79 in) 2.250 Fig. 25 Hore {0.04 ~0.16) ‘Wan fiting length especies ar 20 — 26 10,78 - 0.98) 1-4 (0.08 - 0.16) Units mm (in) When tating lang isnot specified Fig, 26 2.260 Tightening torque: 1.0 — 1.5 Nem (0. = 0.15 keg-m, 0.7 — 1.1 ft-lb) 3. Fuel Filler Pipe A: REMOVAL 1) Open fuel filler flap and remove filler cap. 2) Completely drain fuel from fuel tank. 3) Remove right rear tire. 4) Remove three screws holding packing in place. Fig. 27 5) Remove fuel filler pipe protector. Fig. 28 20FUEL SYSTEM 6) Remove clips and disconnect fuel filler hose and air vent hose from fuel filler pipe. Fig. 29 7) Disconnect fuel filler pipe from underside of c: Place a container under pipe connection to catch fuel which may remain in filter pipe. INSTALLATION {w380]_2-8 3) If edges of rubber packing are folded toward the inside, straighten it with a standard screwdriver. 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 clamps. Do not allow clips to touch air vent hose, air breather hoses and rear suspension cross- member. 5) Insert air vent hose approximately 25 to 30 mm (0.98 10 1.18 in) into the lower end of air vant pipe and tighten with clips, Fuel retura tne: 1L= 20 ~28 mm (0.79 ~ 0.98 in) Evaporation ile: = 18 —20 mm (0.59 ~ 0.79 in) 32.250) 1) Hold fuel filer flap open. 2) Insert fuel filler pipe into hole inner side of apron. Align hol and packing and tighten screws, fuel saucer from the in fuel filler pipe neck Filer exp Tapping serew 2.284) Fig. 30 Fig. 31 6} Install protector together with fue! filler pipe. Check to be sure clamp for filler hose and clip for air vent hose. do not touch body. a2-8 [waall 4, Fuel Filter A: REMOVAL 1, MPFI AND SPFI MODELS 1) Release the fuel pressure. Refer to Section 1. [W101] FUEL SYSTEM 2-160] Fig. 32 2) Loosen the screw of the hose clamp and pull off the hose from the fit 3) Remove the filter from the holder. Fig. 33 2, CARBURETOR MODEL 1) Remove the fuel filter from the holder. 2) Unfasten the clip which connects the fuel hose to the fuel filter and disconnect the hose. B: INSPECTION 1) Check the inside of the filter for dirt and water sedi- ment. 2) If the filter is clogged or cracked, or if the replace- ‘ment interval has been reached, replace the filter. 3) If water is found in the filter, shake the filter with its inlet port facing down, to expel the water. C: INSTALLATION 1. MPFI AND SPFI MODELS 1) Connect the hose as illustrated below: Fig, 36 2) Tighten the hose clamp screw to the specified torque. Tightening torque: 1.0 — 1.5 Nem (0.1 — 0.15 kg-m, 0.7 — 1.1 ft-lb) 22 (FUEL SYSTEM 80) 2-8 3) If the hose is damaged at the clamping portion, replace the hose with a new one. 4) If the hose clamp is too deformed, replace with a new one. 5) Fit the hose to the filter, then install the filter to the holder. Correct the hose position by removing any twist 80 that it will not interfere with the filter body or washer tank, before tightening the screw of the hose clamp. 2, CARBURETOR MODEL 1) Connect the hose as illustrated below: 1, MPFI AND SPFI MODELS 1) Release the fuel pressure. Refer to Section 1. [W101] 2) Keep the connector disconnected. 3) Loosen the hose clamp, and disconnect the hose. Put hose on nipple a ‘Hose (sub-dalivery) faresieooe, gp. Z 22.205 Fig. 37 Hose: 4) Remove the eight nuts and detach fuel pump ASSY. (ZZZZZ IIL ce 21.208 Fig. 36 2) Install the filter to the holder. 5, Fuel Pump REMOVAL Fig. 38 2. CARBURETOR MODEL 1) Remove floor mat from luggage compartment. 2) Remove access hole li 3) Disconnect the wiring connector of the fuel pump. 4) Loosen the hose clamp, and disconnect the hose. 5) Remove the eight nuts and detach fuel pump ASSY. INSPECTION 1) Connect the leads to the harness connector, end apply a 12-volt power supply to check whether the pump operates. a. Keep the battery apart from the pump as far as possible. b, Be sure to turn the 12 V supply ON and OFF on the battery side. ¢. Do not run the pump for a tong time under non- loaded condition.2-8 [W5CO] C: INSTALLATION Installation is in the reverse order of removal proce- dures, Observe the following: (1) Discard old gasket after removal. Replace with a new one. (2) Ensure sealing portion is free from fuel or foreign particles before installation. (Wipe unit mounting holes, packing, ete. with a cloth.) (3) Tighten nuts in numerical sequence shown below, to specified torque. FUEL SYSTEM 6. Fuel Meter Unit ‘A: REMOVAL 1) Fuel meter unit is built into fuel pump ASSY. Before disconnecting hoses, relieve fuel pressure as outlined under "REMOVAL" for fuel pump (MPFl and SPFI mod- els only). 2) Loosen hose clamp, and disconnect the hose. Hote {deivery) 7 Howe (retura) Tightening torque: 3—6 Nem (0.3 — 0.6 kg-m, 2.2 — 4.3 ft-lb) Fig. 39 (4) Install O-ring, then access hole lid. Fig. 40 Fig. 41 B: INSTALLATION Refer to “INSTALLATION” for fuel pump. 24FUEL SYSTEM [w7B0]_2-8 7. Fuel Meter Unit (4WD model only) ‘Two fuel meter units are utilized on 4WD models. A; REMOVAL 1) Remove floor mat from luggage compartment. 2) Remove access hole lid. 3} Disconnect harness connector from fuel meter unit. 4 B: INSTALLATION Installation is in the reverse order of removal proce- dures. Observe the following: (1) Discard old packing (851254A000) after removal. Replace with new. (2) Ensure sealing portion is free from fuel or foreign particles before installation. (Wipe unit mounting holes, packing, etc. clean with a cloth.) (3) Tighten nuts in numerical sequence shown below, to specified torqu Fig. 42 4) Remove five nuts and detach fuel meter unit, Fig. 44 {4) Install O-ring, then access hole lid, Fig. 43 252-8 [wsA0] FUEL SYSTEM. 8, Fuel Separator (4WD model only) ‘A: REMOVAL 1) Remove right trim from luggage compartment. 2) Remove hose protector. (Sedan only) 3) Remove bracket. Be sure not to scratch inner side of car body. 4) Disconnect evaporation hoses from separator. B: INSTALLATION Installation is in the reverse order of removal. Observe the following: ‘. Ensure proper connections. a lubricant. b, When connecting tubes, do not uge soepy water as Fig, 46 Wagon Fig. 47 26 2273FUEL SYSTEM [woo] 2-8 t and fuel tank. » 9. Fuel Delivery, Return and 2) Remove inner trim, insulator, : . 1 Remove fuel delivery pipes and hoses, fuel return pipes Evaporation Lines ‘and hoses, and evaporation pipes and hoses. A: REMOVAL 1) Before disconnecting hoses, relieve fuel pressure as ‘outlined under fuel pump “REMOVAL”. e409 Fig. 48 FWD model 272-8 [weAo] FUEL SYSTEM B2701 Fig. 49 4WD model 2) In engine compartment, detach fuel delivery hoses, return hoses, evaporation tubes and canister. uel return howe Fearne Fust dalvery Fig. 51 SPFl and MPFI models 8277 28FUEL SYSTEM {wioco]_2. When air is gently blown a a soso Terai aso anaes Te through pips (canister side) eee Be careful not to inhale vapor when placing hose to mouth. C: INSTALLATION Fig. 52 Carburetor model Install two-way valve with “TO ENGINE” mark facing the engine (canister hose). B: INSTALLATION }) Install in the reverse order of removal, 1) Connect delivery hose to delivery pipe with an over- lap of 20 to 25 mm (0.79 to 0.98 in). 2) Connect delivery hoses and fuel return hose to fuel tank until they reach the base of each pipe. 3) Insert evaporation tube into evaporation pipe by approx. 15 mm (0.59 in) and position a clip with approx. 8 mm (0.31 in) from hose end. 4) Be sure to inspect hoses and their connections for any leakage of fuel. 10. Two-way Valve A; REMOVAL Remove hoses from two-way valve. oO 2 B: INSPECTION ‘From tenk ‘To cankstor Connect 60 to 100 mm length of hose to two-way valve connections (tank and canister sides). Blow air through pipe to check valve operation. Betta Fig. 63 29‘8 [Tooo} FUEL SYSTEM T_TROUBLESHOOTING Trouble and possible cause Corrective action 7: lnsfficiont fuel supply to tha injector (or carburetor) 1)_[ Fuel pump will not operate, ‘© Defective terminal contact. Tnspact connections, especialy ground, and tighten eecurely. ‘© Trouble in elestromagnetic or electronic circuit parts. Replace fuel pump. 2) _| Lowering of fuel pump function. Replace fuel pump. 3)__ | Clogged dust or water in the fuel fier. Replace fuel fier, claan or replace fuel tank. 4) _ | Clogged o bent fuel pipe or hose. (Goan, correct or replace fuel pipe or hose. 8) _| Airis mixed in the fuet systern. Inspect or retighten each connection part @)_| Clogged or bent air breether tube or pipe. (lean, correct oF replace ar breather tube or pipe. 7) _| Demaged diaphragm of pressure regulator. Foplace. ®) | Fusl damper will not operate, Ropiace. 2. Leakage or blow out fuel 1} | Loosaned joints of the fuel pipe. Retightening. 2) | Cracked fuel pipe, hose and fuel tank. Replace. '3)__[ Defective welding part on the fuel tank. Roplace, 4) [Defective drain packing of the fuel tank. Replace, 5) _| Clogged or bent al brosthor tubo or alr vont tube. Caan, correct or replace ar bresther tubs or alr vert tube. '3. Gasoline is smeling inside of compariment Loosened joints at air breather tubo, alr ant tube and fue flor 2 | pipe. an 2) _| Defective packing air tightness on the fuel saucer. Correct ot replace packing. 3) | Cracked fuel separator. Replace separator. 4, Detective fuel metor indleator 1)__[ Defective operation of fuel meter unit. Replace. 2)__ | Defective operation of fuel meter. 8. Noloe 1) [Large operation noise or vibration of fuel pump. ‘8, When the vehicle is left unattended for an extended period of time: 1) Water may accumulate in the fuel tank. To prevent water condensation, top off the fuel tank or drain the fuel completely. 2) Droin water condensation from the fuel filter. the fuel tank. 1) Rofill the fuel tank while there is still some fuel left in the tank. ¢. Protecting the fuel system against freezing and water condensation. 1) Cold ereas In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below 0°C {82°F) 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- hal After the winter season, drain water which may have accumulated in the fuel filter and fuel tank in the man- er same as thet described under the Moderate Areas. 2) Moderate ‘When water condensation is noticed 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. © Observe the instructions, notes, ete., indicated on the label affixed to the anti-freeze solution (water removing agent) container before use.