Subaru Legacy III (2000-2003 year). Manual - part 42

FU(H4SO)-70

FUEL INJECTION (FUEL SYSTEMS)

FUEL DELIVERY, RETURN AND EVAPORATION LINES

28.Fuel Delivery, Return and 

Evaporation Lines

A: REMOVAL

1) Set the vehicle on the lift.
2) Release the fuel pressure. <Ref. to FU(H4SO)-
48, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>

3) Open the fuel filler flap lid, and then remove the
fuel filler cap.
4) Remove the floor mat.  <Ref. to EI-48, REMOV-
AL, Floor Mat.>
5) Remove the fuel delivery pipes and hoses, fuel
return pipes and hoses, evaporation pipes and hos-
es.

6) In engine compartment, detach the fuel delivery
hoses, return hoses and evaporation hose.

7) Lift-up the vehicle.

8) Disconnect the two-way valve hose (A) from the
two-way valve and disconnect evaporation hose
(B) from evaporation pipe.

9) Separate the quick connector on fuel delivery
and return line.

(1) Clean the pipe and connector, if they are
covered with dust.
(2) Hold the connector (A) and push retainer (B)
down.
(3) Pull out the connector (A) from retainer (B).

FU-00687

FU-00032

FU-00674

( A )

( B )

FU(H4SO)-71

FUEL INJECTION (FUEL SYSTEMS)

FUEL DELIVERY, RETURN AND EVAPORATION LINES

NOTE:
Replace the retainer with new ones.

B: INSTALLATION

1) Connect the quick connector on fuel delivery and
return lines.

NOTE:
• Always use a new retainer.
• Make sure that the connected portion is not dam-
aged or has dust. If necessary, clean the seal sur-
face of pipe.

(1) Set a new retainer (B) to connector (A).
(2) Push the pipe into connector completely.

NOTE:
At this time, two clicking sounds are heard.

NOTE:
• Pull the connector to ensure it is connected se-
curely.
• Ensure the two retainer pawls are engaged in
their mating positions in the connrcotr.
• Be sure to inspect the hoses and their conections
leakage of fuel.

2) Connect the fuel delivery hose to pipe with an
overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When fitting length is specified.
Type B: When fitting length is not specified.

2

 : 2.5

±±±±

1.5 mm (0.098

±±±±

0.059 in)

(A) Connector

(B) Retainer

(C) Pipe

(A) Seal surface

FU-00124

( A )

( B )

( C )

FU-00125

(A) Connector

(B) Retainer

(C) Pipe

(A) Connector

(B) Retainer

(C) Pipe

FU-00126

( A )

( B )

( C )

FU-00127

( A )

( B )

( C )

FU(H4SO)-72

FUEL INJECTION (FUEL SYSTEMS)

FUEL DELIVERY, RETURN AND EVAPORATION LINES

L: 22.5

±±±±

2.5 mm (0.886

±±±±

0.098 in)

3) Connect the evaporation hose to pipe by approx.
15 mm (0.59 in) from hose end.

L = 17.5

±±±±

2.5 mm (0.689

±±±±

0.098 in)

NOTE:
Be sure to inspect the hoses and their connections
for any leakage of huel.

C: INSPECTION

1) Make sure that there are no cracks on the fuel
pipes and fuel hoses.
2) Make sure that the fuel pipe and fuel hose con-
nections are tight.

(1) Fitting

(2) Clamp

(3) Hose

(A) Type A

(B) Type B

(1) Hose

(2) Clip

(3) Pipe

( 1 )

( 2 )

( 3 )

FU-00688

L

( A )

( B )

( 1 )

( 2 )

( 3 )

FU-00129

L

L/2

FU(H4SO)-73

FUEL INJECTION (FUEL SYSTEMS)

FUEL SYSTEM TROUBLE IN GENERAL

29.Fuel System Trouble in General

A: INSPECTION

NOTE:
• When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.
To prevent water condensation.

(1) Top off the fuel tank or drain the fuel completely.
(2) Drain water condensation from the fuel filter.

• Refilling the fuel tank.
Refill the fuel tank while there is still some fuel left in the tank.
• Protecting the fuel system against freezing and water condensation.

(1) Cold areas
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below
0

°

C (32

°

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-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 below.
(2) Affected 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.

• Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water remov-
ing agent) container before use.

Trouble and possible cause

Corrective action

1. Insufficient fuel supply to the injector

1)

Fuel pump will not operate.

❍

Defective terminal contact.

Inspect connections, especially ground, and tighten 
securely.

❍

Trouble in electromagnetic or electronic circuit parts.

Replace the fuel pump.

2)

Lowering of fuel pump function.

Replace the fuel pump.

3)

Clogged dust or water in the fuel filter.

Replace the fuel filter, clean or replace the fuel tank.

4)

Clogged or bent fuel pipe or hose.

Clean, correct or replace the 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 the 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 the 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 the separator.

4)

Inoperative fuel pump modulator or circuit.

Replace.

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.