Subaru Forester Installation and operation manual

Technicians
Reference
Booklet
Evaporative
System Diagnosis
MSA5P0922C
September2003

2000 Model Year Evaporative System Diagnosis
3 Effective 09-25-03
© Copyright 2003
Subaru of America, Inc.
All rights reserved. This book may not be reproduced
in whole or in part without the express permission of
Subaru of America, Inc.
Subaru of America, Inc. reserves the right at any time
to make changes or modifications to systems,
procedures, descriptions, and illustrations contained
in this book without necessarily updating this
document. Information contained herein is considered
current as of September 2003.
© Subaru of America, Inc. 2003

4Effective 09-25-03
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS
Introduction ........................................................................................................................ 6
Legend ................................................................................................................................6
Test Sequence..................................................................................................................... 7
Purge System Test .............................................................................................................. 9
Purge Line 10F..............................................................................................................11
Purge Line 13F..............................................................................................................11
Purge Line 13G .............................................................................................................11
Purge Line 13I..............................................................................................................11
Purge Line 16F............................................................................................................. 13
Purge Line 16F18......................................................................................................... 13
Purge Line 16F34......................................................................................................... 15
Drain System Test............................................................................................................. 16
Drain System Test 9F .................................................................................................. 17
Drain Line System 12F ................................................................................................ 17
Shut Off Valve Test........................................................................................................... 19
Shut Off Valve Test 6F ................................................................................................ 21
Shut Off Valve Test 6F12 ............................................................................................ 21
Shut Off Valve Test 9F ................................................................................................ 23
Shut Off Valve Test 9G................................................................................................ 23
Pressure Control Valve Test.............................................................................................. 25
Fuel Tank and Vent Control Valve Fuel Tank and Vent Control Valve Test...................... 26
Fuel Tank and Vent Control Valve Test 10F ................................................................ 29
Fuel Tank and Vent Control Valve Test 13F ................................................................ 29
Canister Test ..................................................................................................................... 30

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IntroductionIntroduction
IntroductionIntroduction
Introduction
Testingtheonboardrefueling vaporrecoverysysteminvolvescheckingallsolenoids,valvesandplumbingfor
airtightness,air flowandproper operation.Afailureinanyoftheseitemswillcreateafailureinthesystem.
Theevaporativesystempressure testermustbeusedwith theSelectmonitortoachieve thecorrectresults.
Beginbyfirstreadingthewarningsincludedwiththespecialtool.Section bySectiontestingwillensureall
fittings,hoses,pipes,valvesandcomponentsaretested.
LegendLegend
LegendLegend
Legend
PT......... PressureTester F ........... Fuel
CPC ..... CanisterPurgeControl FH ........ FuelHose
M.......... Manifold PCV ..... PressureControlValve
D .......... Drain V .......... Vent
SOV ..... ShutOffValve PS......... PressureSensor
Pressurize
Thisishow youpressurizethe testerwhen
instructed to do so.
1. Place Pressure hold in open position.
2. Place Vent in closed position.
3. Turn the pump timer on.
4. Observe gauge.
5. When highest pressure is reached place the
Pressure hold in closed position.
6. Turnpumptimeroff.

2000 Model Year Evaporative System Diagnosis
7 Effective 09-25-03
Test SequenceTest Sequence
Test SequenceTest Sequence
Test Sequence
1. PurgeSystemTest---------------------------------------------------------------------------------------------7
2. Drain System Test ----------------------------------------------------------------------------------------- 14
3. Shut Off Valve Test ---------------------------------------------------------------------------------------- 17
4. Pressure Control Valve Test ------------------------------------------------------------------------------ 21
5. Fuel Tank and Vent Control Valve Test ----------------------------------------------------------------- 22
6. Canister------------------------------------------------------------------------------------------------------ 28
• Follow the directions in each of the above tests.
• At the end of a given test a stop sign will appear to signify that you need to go to the next test.
• Complete all 6 tests to evaluate the entire evaporative system.
• Directions are included in each test that guides you through results that indicate a failure.
• Always complete the 6 tests even if a failure has been found and repaired early in the test
sequence.
Abbreviation Component Location
CPC CanisterPurgeControlSolenoid Rightundersideofintakemanifold.
PCV Pressurecontrolvalve Abovereardifferential.
D Drainvalve Abovecanisterrightrearofvehicle.
SOV Shut OffValve Locatedonthefuelfiller neck
behindtherightrearinner fender.
PT-1
Adapter2 STPlug
Adapter1

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2000 Legacy Purge Line2000 Legacy Purge Line
2000 Legacy Purge Line2000 Legacy Purge Line
2000 Legacy Purge Line
Purge
Drain
Shut off Valve
Pressure Control Valve
Fuel Tank and
Vent Control Valve
Canister

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Purge System TestPurge System Test
Purge System TestPurge System Test
Purge System Test
(1) Disconnect CPC-1 from M-1.
(2) Startengine andcheckforstrong
vacuum source at M-1.
(3) Engine off and ignition off
(4) Connect select monitor to data link
connector.
(5) Connect inspection mode connectors.
(6) Ignition on and engine off
(7) Turn on select monitor and adjust to
system operation check mode.
Activate a component and turn it off to establish
full control of all system operation check mode
items.
Step 8 and 9 will test the air tightness of the
vacuum line from the intake manifold to the
canister purge control solenoid. The air tightness
of the solenoid is checked at this time also.
(8) Connect PT-1 to CPC-1 and
“pressurize”.
(9) Did pressure hold?
YES go to step (10).
NO go to step (10F).
Step 10 and 11 will test the electrical and
mechanicaloperationofthecanister purgecontrol
solenoid and the vacuum line from the out put
side of the solenoid to the canister for restrictions
or blockages.
(10) Disconnect CPC-16 from canister.
Picture 112.
(11) Activate CPCsolenoidwithselectmonitor.
(12) Didpressuregotozeroimmediately?
YES go to step (13).
NO go to step (13F).
Step 13 and 14 will test the vacuum hose from the
canister purge control solenoid to the canister for
air tightness.
(13) Insert ST plug into CPC-16 to block
hose.
(14) Pressurize.
(15) Did pressure hold?
YES go to step (16).
NO go to step (16F).
(16) Turn CPC solenoid off with select
monitor.
(17) Remove PT-1 from CPC-1.
(18) Connect CPC-1 to M-1.
(19) Remove ST plug from CPC-16.
(20) Connect CPC-16 to canister.
Notes:
STOPSTOP
STOPSTOP
STOP
112
FuelTank
F-1
Purge Hose
CPC-16 Drain Hose
D-1

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2000 Legacy Purge Line2000 Legacy Purge Line
2000 Legacy Purge Line2000 Legacy Purge Line
2000 Legacy Purge Line

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Purge Line 13FPurge Line 13F
Purge Line 13FPurge Line 13F
Purge Line 13F
(13F) Turn offCPCsolenoidwithselect
monitor.
(13F1) Disconnect CPC-4 from CPC-5.
(13F2) Pressurize and turn on CPC solenoid with
select monitor.
(13F3) Does pressure go to zero immediately?
NO go to step (13F4).
YES go to step (13G).
(13F4) Turn off CPC solenoid with select
monitor and connect CPC-4 to CPC-5.
(13F5) Disconnect CPC-3 from CPC solenoid.
(13F6) Pressurize.
(13F7) Turn on CPC solenoid with select
monitor.
(13F8) Does pressure go to zero immediately?
YES – Replace hose “CPC-3 to CPC-4”
and go to step 8.
NO – Replace CPC solenoid and go to
step 8.
(13G5) Pressurize.
(13G6) Disconnect CPC-7 from CPC-8.
(13G7) Doespressurego tozeroimmediately?
YES – Replace hose “CPC-7 to CPC-8”
and go to step (8).
NO – An obstruction exists in the metal
hose from “CPC-5 to CPC-6”,
clean and remove obstruction or replace
hose. Then go to step (8).
(13H) Connect adapter-1 to PT-1.
(13H1) Connect adapter-1 to CPC-8.
(13H2) Pressurize.
(13H3) Disconnect CPC-12 form CPC-13.
(13H4) Does pressure drop to zero immediately?
YES go to step (13I).
NO go to step (13H5).
(13H5) Pressurize.
(13H6) Disconnect CPC-10 from CPC-11.
(13H7) Does pressure drop to zero immediately?
YES – Replace hose “CPC-11 to CPC-
12” and go to step (8).
NO – An obstruction exists in the metal
hose between “CPC-10 and CPC-9” clean
and remove obstruction or replace hose.
Then go to step (8).
Purge Line 13IPurge Line 13I
Purge Line 13IPurge Line 13I
Purge Line 13I
(13I) Connect adapter-1 to CPC-13.
(13I1) Pressurize.
(13I2) Disconnect CPC-14 to CPC-15.
(13I3) Didpressuredrop tozeroimmediately?
YES – Replace hose “CPC-15 to CPC-16”
and go to step (8).
NO – An obstruction exists in the metal
hose between “CPC-13 and CPC-14”,
clean and remove obstruction or replace
hose. Then go to step (8).
Purge Line 10FPurge Line 10F
Purge Line 10FPurge Line 10F
Purge Line 10F
(10F) DisconnectCPC-2fromCPCsolenoid.
(10F1) Connect ST plug to CPC-2.
(10F2) Pressurize.
(10F3) Doespressurehold?
YES – Replace CPC solenoid and
go to step 8.
NO – Replace hose and go to step 8.
Purge Line 13GPurge Line 13G
Purge Line 13GPurge Line 13G
Purge Line 13G
(13G) TurnoffCPCsolenoidwithselect
monitor.
(13G1) Connect PT-1 to CPC-5.
(13G2) Pressurize.
(13G3) Disconnect CPC-8 from CPC-9.
(13G4) Does pressure go to zero immediately?
YES go to step (13H).
NO go to step (13G5).

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2000 Legacy Purge Line2000 Legacy Purge Line
2000 Legacy Purge Line2000 Legacy Purge Line
2000 Legacy Purge Line

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Purge Line 16FPurge Line 16F
Purge Line 16FPurge Line 16F
Purge Line 16F
(16F) TurnCPCsolenoidoffwithselect monitor.
(16F1) Disconnect CPC-14 from CPC-15.
(16F2) Connectadapter-1 with ST plug to CPC-
14.
(16F3) Pressurize.
(16F4) Turn CPC solenoid on with select
monitor.
(16F5) Does pressure hold?
NO go to step (16F6).
YES – Replace hose “CPC-15 to CPC-
16”.
(16F6) Turn CPC solenoid off with select
monitor.
(16F7) Disconnect “CPC-12 to CPC-13”.
(16F8) Connect ST Plug to CPC-12.
(16F9) Pressurize.
(16F10) Turn CPC solenoid on with select
monitor.
(16F11) Does pressure hold?
YES – Replace metal hose “CPC-13 to
CPC-14” and go to step 8.
Ensure hoses disconnected in prior step,
have been reconnected.
NO – Go to (16F12)
(16F12) Turn CPC solenoid off with select
monitor.
(16F13) Disconnect CPC-10 from CPC-11.
(16F14) Connect adapter-1 with ST plug to CPC-
10.
(16F15) Pressurize.
(16F16) Turn CPC solenoid on with select
monitor.
(16F17) Does pressure hold?
YES – Replace hose “CPC-11 to CPC-
12” and go to step 8.
NO – Go to (16F18).
Purge Line 16F18Purge Line 16F18
Purge Line 16F18Purge Line 16F18
Purge Line 16F18
(16F18) TurnoffCPCsolenoidwithselectmonitor.
(16F19) Disconnect CPC-8 from CPC-9.
(16F20) Connect ST Plug to CPC-8.
(16F21) Pressurize.
(16F22) TurnCPCsolenoidonwithselectmonitor.
(16F23) Doespressurehold?
YES – Replace metal hose “CPC-9 to
CPC-10” and go to step (8).
Ensure hoses disconnected in prior step,
have been reconnected.
NO go to step (16F24).
(16F24) Turn off CPC solenoid with select
monitor.
(16F25) Disconnect CPC-6 from CPC-7.
(16F26) Connect adapter-1 with ST plug to CPC-
6.
(16F27) Pressurize.
(16F28) Turn CPC solenoid on with select
monitor.
(16F29) Does pressure hold?
Notes:

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2000 Legacy Purge Line2000 Legacy Purge Line
2000 Legacy Purge Line2000 Legacy Purge Line
2000 Legacy Purge Line

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2000 Model Year Evaporative System Diagnosis
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Purge Line 16F34Purge Line 16F34
Purge Line 16F34Purge Line 16F34
Purge Line 16F34
(16F34) Doespressurehold?
YES – Replace metal hose “CPC-5 to
CPC-6” and go to step (8).
NO – Go to step (16F35).
(16F35) Disconnect CPC-3 from CPC solenoid.
(16F36) Connect adapter-1 with ST plug to CPC
solenoid.
(16F37) Pressurize.
(16F38) Turn CPC solenoid on with select
monitor.
(16F39) Does pressure hold?
YES – Replace hose “CPC-3 to CPC-4”
and go to step (8).
NO – Replace CPC solenoid and go to
step (8).
Notes:

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2000 Legacy Drain Line2000 Legacy Drain Line
2000 Legacy Drain Line2000 Legacy Drain Line
2000 Legacy Drain Line
Drain System TestDrain System Test
Drain System TestDrain System Test
Drain System Test
Steps1through4aretestingtheairtightnessofthe
adapter.
(4) Doespressure hold?
YES go to step (5).
NO, replaceAdapter-1 and go to step (1).
(5) Remove ST-plugfromST-adapter-1.
Step 6 and 7 will test the drain hoses,
canister,drainvalveandfilterforrestrictions
andblockages.
(6) Connect ST-adapter-1withD-1hose.
(7) Pressurize.
(8) Didpressurebuildup?
NO go to step (9).
YES go to step (9F).
Step 9 and 10 will test the air tightness of the vent
hoses from the canister to the drain valve and the
mechanical and electrical operation of the drain
valve.
(9) Activate vent valve solenoid with select
monitor.
(10) Pressurize.
(11) Does pressure hold for the time the
solenoid is on and then drop to zero?
YES go to step (12).
NO go to step (12F).
(12) Turn off vent valve solenoid with select
monitor.
(13) Remove ST adapter-1 from D-1.
(14) Connect D-1 to canister.
(1) DisconnectD-1 fromcanister.Picture115.
(2) Connect PT-1 with STadapter-1.
(3) Block ST adapter-1 withSTPlugand
pressurize. STOPSTOP
STOPSTOP
STOP
Notes:
Purge
Drain
Shut off Valve
Pressure Control Valve
Fuel Tank and
Vent Control Valve
Canister
115
DrainValve

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Drain System Test 9FDrain System Test 9F
Drain System Test 9FDrain System Test 9F
Drain System Test 9F
(9F) DisconnectD-5fromfilter.
(9F1) Pressurize
Didpressurehold?
YES go to step (9F2).
NO , replace hose from D-5 to D-6 or
remove obstruction from hose.
(9F2) Disconnect D-4 from filter.
(9F3) Pressurize
Did pressure hold?
YES go to step (9F4).
NO , replace filter
(9F4) Disconnect D-3 from Drain Valve.
(9F5) Pressurize
Did pressure hold?
YES go to step (9F6).
NO , replace hose from D-3 to D-4 or
remove obstruction from hose.
(9F6) Disconnect D-2 from Drain Valve.
(9F7) Pressurize
Did pressure hold?
YES , replace hose from D-1 to D-2 or
remove obstruction from hose.
NO , replace Drain Valve
Reconnect all hose.
Drain Line System 12FDrain Line System 12F
Drain Line System 12FDrain Line System 12F
Drain Line System 12F
(12F) Disconnect D-2 from Drain Valve
(12F1) Insert adapter –1 with ST plug into D-2
hose.
(12F2) Pressurize
Did pressure hold?
YES, replace Drain Valve and go to step
9.
NO, replace hose from D-1 to D-2 an go
to step 9.
Notes:

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2000 Model Year Evaporative System Diagnosis
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Purge
Drain
Shut off Valve
Pressure Control Valve
Fuel Tank and
Vent Control Valve
Canister

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Shut Off Valve TestShut Off Valve Test
Shut Off Valve TestShut Off Valve Test
Shut Off Valve Test
Step 1 through 4 tests the vacuum hose from
SOV-12 to the shut off valve, the shut off valve
itself, and the vacuum hose from the shut off
valvetothepressurecontrolvalveforrestrictionsand
blockages.
(1) Disconnect SOV-12fromF-4.
(2) Disconnect PCV-1fromPCV.
(3) Connect PT-1 to SOV-12.
(4) Pressurize.
(5) Doespressure buildup?
NO go to step (6).
YES go to step (6F).
Step 6 and 7 will test the air tightness of the
vacuum hose from SOV-12 to the shut off
valve, the shut off valve itself, and the vacuum
hose from the shut off valve to the pressure
controlvalve.
(6) Connect STPlug to PCV-1.
(7) Pressurize.
(8) Didpressurehold?
YES go to step (9).
NO go to step (9F).
(9) Remove Pt-1 from Sov-12 and connect
Sov-12 to F-4.
Notes:
STOPSTOP
STOPSTOP
STOP

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Shut Off Valve Test 6F12Shut Off Valve Test 6F12
Shut Off Valve Test 6F12Shut Off Valve Test 6F12
Shut Off Valve Test 6F12
(6F12)Pressurize.
(6F13) Disconnect SOV-2 from SOV-3.
(6F14)Doespressurebuildup?
YES – Replace hose “SOV-1 to SOV-2”
and go to step (3).
NO – Clean or replace metal hose “SOV-
3 to SOV-4” and go to step (3).
Shut Off Valve Test 6FShut Off Valve Test 6F
Shut Off Valve Test 6FShut Off Valve Test 6F
Shut Off Valve Test 6F
(6F) Pressurize.
(6F1) DisconnectSOV-11 from SOV-10.
(6F2) Doespressurebuildup?
YES – Replace hose “SOV-12 to SOV-
11” and go to step (3).
NO – Connect SOV-11 to SOV-10 and go
to step (6F3).
(6F3) Pressurize.
(6F4) Disconnect SOV-8 from SOV-9.
(6F5) Does pressure build up?
YES – Clean or replace metal hose
“SOV-1 to SOV-9” and go to step (3).
NO-Connect SOV-8 to SOV-9 and go to
step (6F6).
(6F6) Pressurize.
(6F7) Disconnect SOV-7 from Fuel Shut Valve.
(6F8) Does pressure build up?
YES – Replace hose “SOV-8 to SOV-7”
and go to step (3).
NO – Connect SOV-7 to Fuel Shut Valve.
(6F9) Pressurize.
(6F10) Disconnect SOV-1 from Fuel Shut Valve.
(6F11) Does pressure build up?
YES – Replace Fuel Shut Valve and go to
step (3).
NO – Connect SOV-1 to Fuel Shut Valve
and go to step (6F12).
Notes:

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