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Home >> Subaru >> 2004 >> Forester XT, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems) (H4DOTC) >> Fuel filler Pipe >> Installation
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Fuel filler Pipe: Installation

  1. Hold the fuel filler flap lid open.
  2. Set the fuel saucer (A) with rubber packing (C) and insert the fuel filler pipe into hole from the inner side of apron.
    Fig 1: Fuel Saucer And Fuel Filler Pipe
    G00966425Courtesy of SUBARU OF AMERICA, INC.
  3. Align the holes in fuel filler pipe neck and set the cup (B), and tighten the screws.
    NOTE: If the edges of rubber packing are folded toward the inside, straighten it with a screwdriver.
    Fig 2: Aligning Holes In Fuel Filler Pipe Neck And Setting Cup
    G00966426Courtesy of SUBARU OF AMERICA, INC.
  4. Install the evaporation pipe.
    Fig 3: Identifying Evaporation Pipe
    G00966427Courtesy of SUBARU OF AMERICA, INC.
  5. Connect the evaporation hose to the pipe.
    Fig 4: Identifying Evaporation Hose To Pipe
    G00966428Courtesy of SUBARU OF AMERICA, INC.
  6. Insert the fuel filler hose (A) approximately 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe and tighten the clamp.
    CAUTION: Do not allow clips to touch evaporation hose (B) and rear suspension crossmember.
    Fig 5: Inserting Fuel Filler Hose Over Lower End Of Fuel Filler Pipe
    G00966429Courtesy of SUBARU OF AMERICA, INC.
  7. Insert the evaporation hose approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe and hold the clip.
    1. L: 27.5+/-2.5 mm (1.083+/-0.098 in) 
    Fig 6: Identifying Dimension Of Inserting Evaporation Hose
    G00966430Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten the bolt which holds the fuel filler pipe bracket on the body.
    1. Tightening torque: 7.5 N.m (0.75 kgf-m, 5.4 ft-lb) 
    Fig 7: Tightening Bolt Which Holds Fuel Filler Pipe Bracket On Body
    G00966431Courtesy of SUBARU OF AMERICA, INC.
  9. Secure the evaporation hose to clip of fuel filler pipe.
    Fig 8: Securing Evaporation Hose To Clip Of Fuel Filler Pipe
    G00966432Courtesy of SUBARU OF AMERICA, INC.
  10. Install the fuel filler pipe protector.
    Fig 9: Identifying Fuel Filler Pipe Protector
    G00966433Courtesy of SUBARU OF AMERICA, INC.
  11. Install the rear right wheel.
    Fig 10: Identifying Rear Right Wheel
    G00966434Courtesy of SUBARU OF AMERICA, INC.
  12. Lower the vehicle.
  13. Tighten the wheel nuts.
  14. Connect the connectors to the fuel pump relay.
    Fig 11: Identifying Fuel Pump Relay
    G00966435Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the battery ground terminal.
    Fig 12: Identifying Battery Ground Terminal
    G00966436Courtesy of SUBARU OF AMERICA, INC.