Fuel Tank: Installation

Support fuel tank with transmission jack and push fuel tank harness into access hole with grommet.
Set fuel tank and temporarily tighten bolts of fuel tank bands.
WARNING: A helper is required to perform this work.

Fig 1: Supporting Fuel Tank With Transmission Jack
Courtesy of SUBARU OF AMERICA, INC.
Connect air vent hose (A) to evaporation pipe assembly and connect evaporation hose (I) to pressure control solenoid valve.

Fig 2: Connecting Air Vent Hose To Evaporation Pipe Assembly
Courtesy of SUBARU OF AMERICA, INC.
Connect fuel filler hose (A) and fuel tank pressure sensor hose (B).

Fig 3: Connecting Fuel Filler Hose (A) And Fuel Tank Pressure Sensor Hose (B)
Courtesy of SUBARU OF AMERICA, INC.
Tighten band mounting bolts.
Tightening torque:

33 N.m (3.4 kgf-m, 25 ft-lb)

Fig 4: Tightening Band Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install rear side fuel tank cover.
Tightening torque:

18 N.m (1.8 kgf-m, 13.0 ft-lb)

Fig 5: Installing Rear Side Fuel Tank Cover
Courtesy of SUBARU OF AMERICA, INC.
Install rear suspension assembly.
WARNING: A helper is required to perform this work.
1. Support rear suspension assembly and then tighten bolts which secure rear suspension assembly.
  Tightening torque:
  
  T1: 172 N.m (17.5 kgf-m, 127 ft-lb)
  
  T2: 108 N.m (11.0 kgf-m, 80 ft-lb)
  
  T3: 66 N.m (6.7 kgf-m, 48 ft-lb)
  
  Fig 6: Tightening Bolts Specified Torque
  Courtesy of SUBARU OF AMERICA, INC.
2. Tighten bolt which holds rear shock absorber to rear suspension arm.
  Tightening torque:
  
  157 N.m (16 kgf-m, 116 ft-lb)
  
  Fig 7: Tightening Bolts Specified Torque
  Courtesy of SUBARU OF AMERICA, INC.
Connect brake pipes to wheel cylinder. (Rear drum brake model)

Fig 8: Connecting Brake Pipes To Wheel Cylinder
Courtesy of SUBARU OF AMERICA, INC.
Install rear brake caliper. (Rear disk brake model)

Fig 9: Installing Rear Brake Caliper
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolt which holds rear brake hoses holding bracket.
Tightening torque:

33 N.m (3.4 kgf-m, 25 ft-lb)

Fig 10: Identifying Parking Brake Cable Holding Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install parking brake cable to cabin by forcibly pushing it forward.
Tighten bolts which hold parking brake cable holding bracket.
Tightening torque:

18 N.m (1.8 kgf-m, 13.0 ft-lb)

Fig 11: Tightening Bolts
Courtesy of SUBARU OF AMERICA, INC.

Tightening torque:

32 N.m (3.3 kgf-m, 23.9 ft-lb)

Fig 12: Tightening Bolts
Courtesy of SUBARU OF AMERICA, INC.
Connect connector to ABS sensor.

Fig 13: Connecting Connector To ABS Sensor
Courtesy of SUBARU OF AMERICA, INC.
Install propeller shaft.
Install rear exhaust pipe and muffler.
NOTE: To facilitate the procedure, apply a coat of SUBARU CRC to matching area of rubber cushions in advance.

SUBARU CRC (Part No. 004301003)
1. Install left and right rubber cushions.
  
  Fig 14: Installing Left And Right Rubber Cushions
  Courtesy of SUBARU OF AMERICA, INC.
2. Install front rubber cushion and attach muffler assembly.
  
  Fig 15: Attaching Muffler Assembly
  Courtesy of SUBARU OF AMERICA, INC.
3. Install rear exhaust pipe to center exhaust pipe.
  Tightening torque:
  
  18 N.m (1.8 kgf-m, 13.0 ft-lb)
  
  Fig 16: Installing Rear Exhaust Pipe To Center Exhaust Pipe
  Courtesy of SUBARU OF AMERICA, INC.
Install front side fuel tank cover.
Tightening torque:

18 N.m (1.8 kgf-m, 13.0 ft-lb)

Fig 17: Installing Front Side Fuel Tank Cover
Courtesy of SUBARU OF AMERICA, INC.
Install rear wheel.
Lower the vehicle.
Tighten wheel nuts to rear wheel.
Install parking brake cable. < Ref. to REMOVAL & INSTALLATION . >

Fig 18: Installing Parking Brake Cable
Courtesy of SUBARU OF AMERICA, INC.
Install console box. < Ref. to INSTALLATION , Console Box. >
Connect fuel hoses and hold them with quick connector. < Ref. to , INSTALLATION , Fuel Delivery, Return and Evaporation Lines. >

Fig 19: Connecting Fuel Hoses And Hold With Quick Connector
Courtesy of SUBARU OF AMERICA, INC.
Connect evaporation pipe (A) and hold it with quick connector. < Ref. to , INSTALLATION , Fuel Delivery, Return and Evaporation Lines. >

Fig 20: Connecting Evaporation Pipe (A) And Hold With Quick Connector
Courtesy of SUBARU OF AMERICA, INC.
Install pipe protector.

Fig 21: Installing Pipe Protector
Courtesy of SUBARU OF AMERICA, INC.
Install trunk room trim. (Sedan model)
Install luggage room trim. (Wagon model)
Connect fuel jet pump hose.

Fig 22: Connecting Fuel Jet Pump Hose
Courtesy of SUBARU OF AMERICA, INC.
Connect connector to fuel sub level sensor.

Fig 23: Connecting Connector To Fuel Sub Level Sensor
Courtesy of SUBARU OF AMERICA, INC.
Install sub service hole cover.

Fig 24: Installing Sub Service Hole Cover
Courtesy of SUBARU OF AMERICA, INC.
Connect connectors to fuel tank cord and plug service hole with grommet.

Fig 25: Connecting Connectors To Fuel Tank Cord And Plug Service Hole With Grommet
Courtesy of SUBARU OF AMERICA, INC.
Install holder clip which secures fuel tank cord on bracket.

Fig 26: Installing Holder Clip Securing Fuel Tank Cord On Bracket
Courtesy of SUBARU OF AMERICA, INC.
Set rear seat and floor mat.
Connect connector to fuel pump relay.

Fig 27: Connecting Connector To Fuel Pump Relay
Courtesy of SUBARU OF AMERICA, INC.
Bleed air from brake system. (Rear drum brake model only) < Ref. to BLEEDING BRAKE SYSTEM . >
Adjust parking brake lever stroke. < Ref. to PARKING BRAKE . >
Check wheel alignment and adjust if necessary. < Ref. to WHEEL ALIGNMENT . >