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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.
    G12391579Courtesy of SUBARU OF AMERICA, INC.
    (a) Position mark (fuel pump)
    (b) Fuel pump installation position range mark (fuel tank)
    (c) Front side of vehicle
  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.
    G16340765Courtesy of SUBARU OF AMERICA, INC.
    (a) Installation start position mark (fuel tank)
    (b) Position mark (ring nut)
    (c) Ring nut
    (e) Gasket
    (d) Ring nut plate
  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 fuel delivery tube with the ST.
    • Before setting the ST, move the fuel delivery 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)

    G16340766Courtesy of SUBARU OF AMERICA, INC.
    (a) Ring nut installation position start mark (fuel tank)
    (b) Position mark (ring nut)
    (c) Ring nut installation position end range mark (fuel tank)
    (d) Fuel pump installation position range mark (fuel tank)
    (e) Position mark (fuel pump)
    (f) Front side of vehicle
  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 

    21.3 - 26.3 mm (0.839 - 1.035 in)

    G16340767Courtesy of SUBARU OF AMERICA, INC.
    (A) Caliper with depth gauge
    (B) Ring nut
    (C) Fuel tank
    (E) Measuring point
    (D) Dimension of ring nut and top of fuel tank
    (F) Front side of vehicle
  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. Set the gasket and install the grommets.
    CAUTION:
    • If the gasket is damaged, replace it with a new part.
    • Make sure that the gasket is installed in the correct orientation.
    • Make sure that the grommets are fully inserted.
    NOTE: If the threaded portion of grommet is faulty, replace the grommet with a new part.
    G14601109Courtesy of SUBARU OF AMERICA, INC.
  10. 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.
    G14601078Courtesy of SUBARU OF AMERICA, INC.
  11. Install the service hole cover RH.
    G13224005Courtesy of SUBARU OF AMERICA, INC.
  12. Install the rear seat cushion. Ref. to SEATS>REAR SEAT>INSTALLATION .
  13. Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
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