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Fuel Pump: Installation

  1. Install a new gasket to the fuel tank.
    G11252951Courtesy of SUBARU OF AMERICA, INC.
  2. Connect the fuel sub delivery tube to the fuel pump assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE D) .
    NOTE: Connect so that the rib (a) of fuel pump assembly aligns between the retainers (b) of quick connector.
    G12391577Courtesy of SUBARU OF AMERICA, INC.
    G12391568Courtesy of SUBARU OF AMERICA, INC.
  3. Set the fuel pump to the position shown in the figure.
    CAUTION:
    • Be careful not to spill any fuel over the gasket. If any fuel is spilled onto the gasket, wipe it off completely. Otherwise the fuel pump may rotate together with the ring nut.
    • Set the arm and float of the fuel level sensor while paying attention to prevent them from contacting the fuel tank. If the arm of the fuel level sensor is bent, the fuel gauge may not read correctly.
    G14383677Courtesy of SUBARU OF AMERICA, INC.
  4. Set a new ring nut plate.
    G12391580Courtesy of SUBARU OF AMERICA, INC.
  5. Set a new ring nut, and align the fuel tank installation start position mark with the ring nut position mark.
    NOTE:
    • Make sure that the ring nut, ring nut plate and gasket are set as shown in the figure.
    • Set the ring nut by firmly pressing against the fuel tank.
    G14383679Courtesy of SUBARU OF AMERICA, INC.
  6. Using the ST, tighten the ring nut by one turn, and then tighten until the ring nut position mark is located within the installation end position range mark on the fuel tank.
    CAUTION:
    • Be careful not to damage the tube with the ST.
    • Before setting the ST, move the tube above the ST.
    • Make sure that the ring nut position mark is located within the installation position end range mark on the fuel tank as shown in the figure.
    • Make sure that the position mark on the fuel pump is located within the installation position range mark on the fuel tank as shown in the figure.

    Preparation tool: 

    ST: ST FUEL PUMP (42099FL000)

    G14383680Courtesy of SUBARU OF AMERICA, INC.
  7. Using a caliper with depth gauge, measure the dimension (3 positions) of the ring nut and the top of fuel tank to check the tightening condition of the ring nut.
    CAUTION:
    • If the measured value exceeds the standard, retighten the ring nut to correct erroneous tightening of the ring nut.
    • If the ring nut and ring nut plate are deformed, cracked or damaged, replace them with new parts.

    Dimension of ring nut and top of fuel tank: 

    Standard 

    23.8 ±2.5 mm (0.937±0.098 in)

    G14383681Courtesy of SUBARU OF AMERICA, INC.
  8. Connect the fuel delivery tube. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE D) .
    G12391566Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the connector to the fuel pump.
    CAUTION: Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel pump and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.
    G12391528Courtesy of SUBARU OF AMERICA, INC.
  10. Install the service hole cover of fuel pump.
    G13224005Courtesy of SUBARU OF AMERICA, INC.
  11. Install the rear seat cushion. Ref. to SEATS>REAR SEAT>INSTALLATION .
  12. Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
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