Fuel Filler Pipe: Installation

Hold fuel filler flap open.
Set fuel saucer (A) with rubber packing (C) and insert fuel filler pipe into hole from the inner side of apron.

Fig 1: Identifying Fuel Saucer And Rubber Packing
Courtesy of SUBARU OF AMERICA, INC.
Align holes in fuel filler pipe neck and set cup (B), and tighten screws.
NOTE: If edges of rubber packing are folded toward the inside, straighten it with a screwdriver.

Fig 2: Identifying Fuel Saucer And Rubber Packing
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolt which holds fuel filler pipe on body.
Tightening torque: 7.5 N.m (0.75 kgf-m, 5.4 ft-lb)

Fig 3: Locating Fuel Filler Pipe Bolt
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Insert evaporation hose approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe and hold clip.

Fig 4: Connecting Evaporation Hose To Fuel Filler Pipe
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L = 27.5±2.5 mm (1.083±0.098 in)

Fig 5: Identifying Evaporation Hose Dimension
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Insert canister hoses approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe assembly and tighten clamp.

Fig 6: Connecting Canister Hose To Evaporation Pipe Assembly
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L = 27.5±2.5 mm (1.083±0.098 in)

Fig 7: Identifying Evaporation Pipe Dimension
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Tighten bolt which holds evaporation pipe assembly on body.
Tightening torque: 7.5 N.m (0.75 kgf-m, 5.4 ft-lb)

Fig 8: Locating Evaporation Pipe Assembly Bolt
Courtesy of SUBARU OF AMERICA, INC.
Insert air vent hose (A), evaporation hose (B) approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe assembly and hold clip.
Insert evaporation hose (C) to pressure control solenoid valve and hold clip.

Fig 9: Disconnecting Air Vent Hose And Evaporation Hose
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L = 27.5±2.5 mm (1.083±0.098 in)

Fig 10: Identifying Evaporation Hose Dimension
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Tighten bolt which holds fuel filler pipe on body and tighten bolt which holds fuel pressure sensor on fuel filler pipe.
Tightening torque: 7.5 N.m (0.75 kgf-m, 5.4 ft-lb)
Insert fuel filler hose approximately 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe and tighten clamp.

Fig 11: Locating Fuel Pressure Sensor Bolts
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Jack-up the rear sub frame and tighten bolts which hold rear sub frame on body.
Tightening torque:

T1: 66 N.m (6.7 kgf-m, 48.5 ft-lb)

T2: 172 N.m (17.5 kgf-m, 127 ft-lb)

Fig 12: Identifying Rear Sub Frame Bolts
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Tighten bolt which holds rear shock absorber to rear suspension arm. < Ref. to INSTALLATION , Rear Shock Absorber . >
Tightening torque: 157 N.m (16 kgf-m, 116 ft-lb)

Fig 13: Locating Rear Suspension Arm Bolt
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Install heat shield cover.

Fig 14: Locating Heat Shield Cover Bolts
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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 15: Locating Left And Right Rubber Cushions
  Courtesy of SUBARU OF AMERICA, INC.
2. Install front rubber cushion and attach muffler assembly.
  
  Fig 16: Locating Front Rubber Cushion
  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 17: Identifying Rear Exhaust Pipe And Center Exhaust Pipe
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Install fuel filler pipe protector.

Fig 18: Identifying Fuel Filler Pipe Protector
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Install rear right wheel.

Fig 19: Identifying Rear Right Wheel
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Lower the vehicle.
Tighten wheel nuts.
Connect battery ground cable.

Fig 20: Connecting Battery Ground Cable
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Remove fuel filler pipe to under side of the vehicle.