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Home >> Subaru >> 2003 >> Outback Base, 4D Sedan >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems, H6DO) >> Fuel Tank >> Installation
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Fuel Tank: Installation

  1. Support fuel tank with transmission jack and push fuel tank harness into access hole with grommet.
  2. Set fuel tank and temporarily tighten bolts of fuel tank bands.
    WARNING: A helper is required to perform this work.
    Fig 1: Tightening Bolts Of Fuel Tank Bands
    G02877225Courtesy of SUBARU OF AMERICA, INC.
  3. Connect air vent hose (A) to evaporation pipe assembly and connect evaporation hose (I) to pressure solenoid valve.
    Fig 2: Connecting Air Vent Hose
    G02877226Courtesy of SUBARU OF AMERICA, INC.
  4. Connect fuel filler hose (A) and fuel tank pressure sensor hose (B).
    Fig 3: Connecting Fuel Filler Hose & Fuel Tank Pressure Sensor Hose
    G02877227Courtesy of SUBARU OF AMERICA, INC.
  5. Tighten band mounting bolts.
    1. Tightening torque:  33 N.m (3.4 kgf-m, 25 ft-lb)
    Fig 4: Tightening Band Mounting Bolts
    G02877228Courtesy of SUBARU OF AMERICA, INC.
  6. Install rear side fuel tank cover.
    1. Tightening torque:  18 N.m (1.8 kgf-m, 13.0 ft-lb)
    Fig 5: Installing Rear Side Fuel Tank Cover
    G02877229Courtesy of SUBARU OF AMERICA, INC.
  7. 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: 

      1. T1:  172 N.m (17.5 kgf-m, 127 ft-lb)
      2. T2:  108 N.m (11.0 kgf-m, 80 ft-lb)
      3. T3:  66 N.m (6.7 kgf-m, 48 ft-lb)
      Fig 6: Supporting Rear Suspension Assembly
      G02877230Courtesy of SUBARU OF AMERICA, INC.
    2. Tighten bolt which holds rear shock absorber to rear suspension arm. < Ref. to INSTALLATION , Link Upper.>
    1. Tightening torque:  157 N.m (16 kgf-m, 116 ft-lb)
    Fig 7: Tightening Rear Shock Absorber Bolt
    G02877231Courtesy of SUBARU OF AMERICA, INC.
  8. Install rear brake caliper. < Ref. to DISC & DRUM .>
    Fig 8: Installing Rear Brake Caliper
    G02877232Courtesy of SUBARU OF AMERICA, INC.
  9. Tighten bolt which holds rear brake hoses holding bracket.
    1. Tightening torque:  33 N.m (3.4 kgf-m, 25 ft-lb)
    Fig 9: Tightening Rear Brake Hoses Bolt
    G02877233Courtesy of SUBARU OF AMERICA, INC.
  10. Install parking brake cable to cabin by forcibly pushing it forward.
  11. Tighten bolts which hold parking brake cable holding bracket.
    1. Tightening torque:  18 N.m (1.8 kgf-m, 13.0 ft-lb)
    Fig 10: Tightening Parking Brake Cable Bolt
    G02877234Courtesy of SUBARU OF AMERICA, INC.
    1. Tightening torque:  32 N.m (3.3 kgf-m, 23.9 ft-lb)
    Fig 11: Tightening Parking Brake Cable Bolts
    G02877235Courtesy of SUBARU OF AMERICA, INC.
  12. Connect connector to ABS sensor.
    Fig 12: Connecting Connector To ABS Sensor
    G02877236Courtesy of SUBARU OF AMERICA, INC.
  13. Install propeller shaft.
  14. 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.
    1. SUBARU CRC (Part No. 004301003) 
    1. Install left and right rubber cushions.
      Fig 13: Installing Rubber Cushions
      G02877237Courtesy of SUBARU OF AMERICA, INC.
    2. Install front rubber cushion and attach muffler assembly.
      Fig 14: Installing Front Rubber Cushion & Attaching Muffler Assembly
      G02877238Courtesy of SUBARU OF AMERICA, INC.
    3. Install rear exhaust pipe to center exhaust pipe.
    1. Tightening torque:  18 N.m (1.8 kgf-m, 13.0 ft-lb)
    Fig 15: Installing Rear Exhaust Pipe To Center Exhaust Pipe
    G02877239Courtesy of SUBARU OF AMERICA, INC.
  15. Install front side fuel tank cover.
    1. Tightening torque:  18 N.m (1.8 kgf-m, 13.0 ft-lb)
    Fig 16: Installing Front Side Fuel Tank Cover
    G02877240Courtesy of SUBARU OF AMERICA, INC.
  16. Install rear wheel.
  17. Lower the vehicle.
  18. Tighten wheel nuts to rear wheel.
  19. Install parking brake cable. < Ref. to DISC & DRUM .>
    Fig 17: Installing Parking Brake Cable
    G02877241Courtesy of SUBARU OF AMERICA, INC.
  20. Install console box. < Ref. to INSTALLATION , Console Box.>
  21. Connect fuel hoses and hold them with quick connector. < Ref. to INSTALLATION , Fuel Delivery, Return and Evaporation Lines.>
    Fig 18: Connecting Fuel Hoses
    G02877242Courtesy of SUBARU OF AMERICA, INC.
  22. Connect evaporation pipe and hold it with quick connector. < Ref. to INSTALLATION , Fuel Delivery, Return and Evaporation Lines.>
    Fig 19: Connecting Evaporation Pipe
    G02877243Courtesy of SUBARU OF AMERICA, INC.
  23. Install pipe protector.
    Fig 20: Installing Pipe Protector
    G02877244Courtesy of SUBARU OF AMERICA, INC.
  24. Install trunk room trim. (Sedan model)
  25. Install luggage room trim. (Wagon model)
  26. Connect fuel jet pump hose.
    Fig 21: Connecting Fuel Jet Pump Hose
    G02877245Courtesy of SUBARU OF AMERICA, INC.
  27. Connect connector to fuel sub level sensor.
    Fig 22: Connecting Connector To Fuel Sub Level Sensor
    G02877246Courtesy of SUBARU OF AMERICA, INC.
  28. Install sub service hole cover.
    Fig 23: Installing Sub Service Hole Cover
    G02877247Courtesy of SUBARU OF AMERICA, INC.
  29. Connect connectors to fuel tank cord and plug service hole with grommet.
    Fig 24: Connecting Connectors To Fuel Tank Cord
    G02877248Courtesy of SUBARU OF AMERICA, INC.
  30. Install holder clip which secures fuel tank cord on bracket.
    Fig 25: Installing Holder Clip
    G02877249Courtesy of SUBARU OF AMERICA, INC.
  31. Set rear seat and floor mat.
  32. Connect connector to fuel pump relay.
    Fig 26: Connecting Connector To Fuel Pump Relay
    G02877250Courtesy of SUBARU OF AMERICA, INC.
  33. Adjust parking brake lever stroke. < Ref. to DISC & DRUM .>
  34. Check wheel alignment and adjust if necessary. < Ref. to INSPECTION , Wheel Alignment.>
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