Fuel Tank: Installation

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

Fig 1: Setting Fuel Tank
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Connect air vent hose (A) to evaporation pipe assembly and connect evaporation hose (B) to pressure control solenoid valve.

Fig 2: Connecting Air Vent Hose To Evaporation Pipe Assembly
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Connect fuel filler hose (A) and fuel tank pressure sensor hose (B).

Fig 3: Connecting Fuel Filler Hose & Fuel Tank Pressure Sensor Hose
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Tighten band mounting bolts.
Tightening torque:
1. 33 N.m (3.4 kgf-m, 25 ft-lb)
Fig 4: Tightening Band Mounting Bolts
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Install rear side fuel tank cover.
Tightening torque:
1. 18 N.m (1.8 kgf-m, 13.0 ft-lb)
Fig 5: Installing Rear Side Fuel Tank Cover
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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 (6.7kgf-m, 48 ft-lb)
  Fig 6: Installing Rear Suspension Assembly
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2. Tighten bolt which holds rear shock absorber to rear suspension arm. Refer to INSTALLATION , Link Upper.
  Tightening torque:
  1. 157 N.m (16 kgf-m, 116 ft-lb)
  Fig 7: Tightening Bolt Which Holds Rear Shock Absorber To Rear Suspension Arm
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Install rear brake caliper. Refer to INSTALLATION , Rear Disc Brake Assembly.

Fig 8: Installing Rear Brake Caliper
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Tighten bolts which hold rear brake hoses holding bracket.
Tightening torque:
1. 33 N.m (3.4 kgf-m, 25 ft-lb)
Fig 9: Tightening Bolts Which Hold Rear Brake Hoses Holding Bracket
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Install parking brake cable to cabin by forcibly pushing it forward.
Tighten bolts which hold parking brake cable holding bracket.
Tightening torque:
1. 18 N.m (1.8 kgf-m, 13.0 ft-lb)
Fig 10: Installing Parking Brake Cable (1 Of 2)
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Tightening torque:
1. 32 N.m (3.3 kgf-m, 23.9 ft-lb)
Fig 11: Installing Parking Brake Cable (2 Of 2)
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Connect connector to ABS sensor.

Fig 12: Connecting Connector To ABS Sensor
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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 13: Installing Left And Right Rubber Cushions
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2. Install front rubber cushion and attach muffler assembly.
  
  Fig 14: Attaching Muffler Assembly
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3. Install rear exhaust pipe to front exhaust pipe.
  Tightening torque:
  1. 18 N.m (1.8 kgf-m, 13.0 ft-lb)
  Fig 15: Installing Rear Exhaust Pipe
  Courtesy of SUBARU OF AMERICA, INC.
Install front side fuel tank cover.
Tightening torque:
1. 18 N.m (1.8 kgf-m, 13.0 ft-lb)
Fig 16: Installing Front Side Fuel Tank Cover
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Install rear wheel.
Lower the vehicle.
Tighten wheel nuts.
Install parking brake cable. Refer to INSTALLATION , Parking Brake Cable.

Fig 17: Installing Parking Brake Cable
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Install console box. Refer to INSTALLATION , Console Box.
Connect fuel hoses and hold them with quick connector. Refer to INSTALLATION , Fuel Delivery, Return and Evaporation Lines.

Fig 18: Connecting Fuel Hoses
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Connect evaporation pipe and hold it with quick connector. Refer to INSTALLATION , Fuel Delivery, Return and Evaporation Lines.

Fig 19: Connecting Evaporation Pipe
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Install pipe protector.

Fig 20: Installing Pipe Protector
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Install trunk trim. (Sedan model) Refer to INSTALLATION , Trunk Trim.
Install rear quarter lower trim. (Wagon model) Refer to REMOVAL , Rear Quarter Trim.
Connect fuel jet pump hose.

Fig 21: Connecting Fuel Jet Pump Hose
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Connect connector to fuel sub level sensor.

Fig 22: Connecting Fuel Sub Level Sensor Connector
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Install sub service hole cover.

Fig 23: Installing Sub Service Hole Cover
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Connect connectors to fuel tank cord and plug service hole with grommet.

Fig 24: Connecting Connectors To Fuel Tank Cord
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Install holder clip which secures fuel tank cord on bracket.

Fig 25: Installing Holder Clip Which Secures Fuel Tank Cord On Bracket
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Set rear seat and floor mat.
Connect connector to fuel pump relay.

Fig 26: Connecting Fuel Pump Relay Connector
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Adjust parking brake lever stroke. .
Check wheel alignment and adjust if necessary. .