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Home >> Subaru >> 2005 >> Outback i, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems) (H4SO) >> Fuel Tank >> Installation
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Fuel Tank: Installation

  1. Support the fuel tank with transmission jack, set the fuel tank, and then temporarily tighten the bolts of fuel tank band.
    WARNING: A helper is required to perform this work.
    Fig 1: Tightening Bolts Of Fuel Tank Band
    G03827777Courtesy of SUBARU OF AMERICA, INC.
  2. Correctly insert the fuel filler hose (A) and evaporation hose (B) to specified position, and then tighten the clamp.
    Fig 2: Insert Fuel Filler Hose And Evaporation Hose To Position (1 Of 2)
    G03827778Courtesy of SUBARU OF AMERICA, INC.
    Fig 3: Insert Fuel Filler Hose And Evaporation Hose To Position (2 Of 2)
    G03827779Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the evaporation hose.
    Fig 4: Connecting Evaporation Hose
    G03827780Courtesy of SUBARU OF AMERICA, INC.
  4. Tighten the bolts of fuel tank band.

    Tightening torque: 

    33 N.m (3.4 kgf-m, 25 ft-lb) 

  5. Connect the connector.
    Fig 5: Connecting Connector
    G03827781Courtesy of SUBARU OF AMERICA, INC.
  6. Install the rear suspension assembly.
    CAUTION: A helper is required to perform this work.
    1. Support the rear differential with transmission jack.
    2. Support the rear suspension assembly, and then tighten the bolts which secure the rear suspension assembly to body.

      Tightening torque: 

      T1: 125 N.m (12.7 kgf-m, 92.2 ft-lb) 

      T2: 65 N.m (6.2 kgf-m, 48 ft-lb) 

      T3: 175 N.m (17.8 kgf-m, 129 ft-lb) 

      Fig 6: Tightening Bolts Securing Rear Suspension Assembly To Body (1 Of 2)
      G03827782Courtesy of SUBARU OF AMERICA, INC.
      Fig 7: Tightening Bolts Securing Rear Suspension Assembly To Body (2 Of 2)
      G03827783Courtesy of SUBARU OF AMERICA, INC.
    3. Tighten the bolts which install the rear shock absorber to rear suspension arm. < Ref. to INSTALLATION , Rear Arm. >

    Tightening torque: 

    62 N.m (6.3 kgf-m, 46 ft-lb) 

    Fig 8: Tightening Bolts Which Install Rear Shock Absorber To Rear Suspension Arm
    G03827784Courtesy of SUBARU OF AMERICA, INC.
  7. Tighten the bolts which install the parking brake cable clamp.

    Tightening torque: 

    18 N.m (1.8 kgf-m, 13.3 ft-lb) 

    Fig 9: Tightening Bolts Which Install Parking Brake Cable Clamp (1 Of 2)
    G03827785Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    32 N.m (3.3 kgf-m, 23.9 ft-lb) 

    Fig 10: Tightening Bolts Which Install Parking Brake Cable Clamp (2 Of 2)
    G03827786Courtesy of SUBARU OF AMERICA, INC.
  8. Connect the connector to rear ABS wheel speed sensor.
    Fig 11: Connecting Connector To Rear ABS Wheel Speed Sensor
    G03827787Courtesy of SUBARU OF AMERICA, INC.
  9. Install the heat shield cover.
  10. Install the propeller shaft. < Ref. to INSTALLATION , Propeller Shaft. >
  11. Install the rear exhaust pipe. < Ref. to INSTALLATION , Rear Exhaust Pipe. >
  12. Lower the vehicle.
  13. Connect the parking brake cable to parking brake assembly. < Ref. to INSTALLATION , Parking Brake Assembly (Rear Disc Brake). >
  14. Install the rear brake caliper.
  15. Tighten the bolt which secures rear brake hose installation bracket.

    Tightening torque: 

    33 N.m (3.4 kgf-m, 25 ft-lb) 

    Fig 12: Tighten Bolt Securing Rear Brake Hose Installation Bracket
    G03827788Courtesy of SUBARU OF AMERICA, INC.
  16. Install the rear wheels.
  17. Lower the vehicle.
  18. Connect the quick connector of evaporation pipe. < Ref. to , INSTALLATION , Fuel Delivery, Return and Evaporation Lines. >
    Fig 13: Connecting Quick Connector Of Evaporation Pipe
    G03827789Courtesy of SUBARU OF AMERICA, INC.
  19. Install pipe protector.
    Fig 14: Installing Pipe Protector
    G03827790Courtesy of SUBARU OF AMERICA, INC.
  20. Install trunk room trim. (Sedan model) < Ref. to INSTALLATION , Trunk Room Trim. >
  21. Install rear quarter trim. (Wagon model) < Ref. to WAGON MODEL , INSTALLATION, Rear Quarter Trim. >
  22. Connect the connector (A) to fuel sub level sensor.
  23. Connect the quick connector to the fuel delivery (B) and return hose (C). < Ref. to , INSTALLATION , Fuel Delivery, Return and Evaporation Lines. >
    NOTE: Be careful not to misconnect the delivery side and return side.
    Fig 15: Connecting Quick Connector To Fuel Delivery And Return Hose
    G03827791Courtesy of SUBARU OF AMERICA, INC.
  24. Install the service hole cover of fuel sub level sensor.
    Fig 16: Installing Service Hole Cover Of Fuel Sub Level Sensor
    G03827792Courtesy of SUBARU OF AMERICA, INC.
  25. Connect the connector (A), and then install the clips (B).
    Fig 17: Connecting Connector And Installing Clips
    G03827793Courtesy of SUBARU OF AMERICA, INC.
  26. Connect the connector to fuel pump.
    Fig 18: Connecting Connector To Fuel Pump
    G03827794Courtesy of SUBARU OF AMERICA, INC.
  27. Install the service hole cover of fuel pump.
    Fig 19: Installing Service Hole Cover Of Fuel Pump
    G03827795Courtesy of SUBARU OF AMERICA, INC.
  28. Install the rear seat.
  29. Install the fuse of fuel pump to main fuse box.
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