Fuel Tank Assembly (Fa20): Installation

1. Install the fuel tank to filler pipe hose to the fuel tank assembly with the clamp.
2. Tighten the hose clamp bolt.

   Standard value: T=2.0N.m {20kgf.cm} {18.0ft.lbf}

   Fig 1: Locating Fuel Tank Hose Clamp

   Courtesy of SUBARU OF AMERICA, INC.

1. Check the fuel tank cover.
   NOTE: As the fuel tank cover is used as a guide when installing the fuel tank Assembly, check for deformation, cracks, and other damages. If there is any problem, replace it with a new part
Fig 2: Identifying Fuel Tank Cover
Courtesy of SUBARU OF AMERICA, INC.
2. Hold the fuel tank Assembly with the transmission jack.
3. Temporarily install the fuel tank Assembly to the body with the two fuel tank bands No. 1 and four bolts.
4. Adjust the fuel tank Assembly position so that the distance from the arrest hole of parking brake cable fixing bracket to the front edge of fuel tank cover is within the standard value.

   Standard value: 42 to 44 mm {1.6535 to 1.7327 in}

   Fig 3: Identifying Fuel Tank Assembly Position

   Courtesy of SUBARU OF AMERICA, INC.
5. Measure the distances from the left and right side of fuel tank Assembly to the body, respectively, and adjust the position of fuel tank Assembly so that the difference between the left and right values is within the standard value.

   Standard value: 2 mm {0.0787 in} or less

   Fig 4: Measuring Fuel Tank Assembly To Body Distances

   Courtesy of SUBARU OF AMERICA, INC.
6. Tighten the four bolts in the order as shown in the figure and install the fuel tank band No. 1.

   Standard value: T=33N.m {337kgf.cm} {24.3ft.lbf}

   Fig 5: Fuel Tank Band No. 1 Bolt Tightening Sequence

   Courtesy of SUBARU OF AMERICA, INC.

1. Connect the fuel tank vent tube as indicated by the arrows in the order shown in the illustration.
   Fig 6: Connecting Fuel Tank Vent Tube

   Courtesy of SUBARU OF AMERICA, INC.

1. Engage the clamp to install the tube.
2. Connect the fuel tank vent hose sub-assembly with the clamp.

1. Connect the fuel tank to filler pipe hose with the hose clamp.

   Standard value: T=2.0N.m {20kgf.cm} {1.5ft.lbf}

1. Install the fuel tank protector with a new nut and two clips.

   Standard value: T=9.0N.m {92kgf.cm} {6.6ft.lbf}

(Refer to INSTALLATION )

1. Connect the fuel sub sender gauge connector.
   Fig 7: Locating Fuel Sub Sender Gauge Connector

   Courtesy of SUBARU OF AMERICA, INC.

1. Connect the fuel delivery tube. (Refer to FUEL SYSTEM (FA20)  )
   Fig 8: Locating Fuel Delivery Tube

   Courtesy of SUBARU OF AMERICA, INC.

1. Connect the fuel pump connector.
   Fig 9: Locating Fuel Pump Connector

   Courtesy of SUBARU OF AMERICA, INC.

Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}

1. Install the rear floor service hole cover using new butyl tape.
   NOTE:

   1. Align the flange of the rear floor service hole cover to the corner bead on the floor.
   2. Align the cutout for the rear floor service hole cover to the floor protrusion.
Fig 10: Aligning Flange And Cutout
Courtesy of SUBARU OF AMERICA, INC.
2. Install the grommet to the rear floor service hole cover.

1. Install the rear floor service hole cover No. 2 using new butyl tape.
   NOTE:

   1. Align the flange of the rear floor service hole cover No. 2 to the corner bead on the floor.
   2. Align the cutout for the rear floor service hole cover No. 2 to the floor protrusion.
Fig 11: Aligning Flange And Cutout
Courtesy of SUBARU OF AMERICA, INC.
2. Install the grommet to the rear floor service hole cover No. 2.