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Fuel Tank: Installation

  1. Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band.
    CAUTION: A helper is required to perform this work.
    G13198349Courtesy of SUBARU OF AMERICA, INC.
  2. Move the fuel tank so that the distance between the end of the reference hole for each body and the end of the fuel tank becomes the following, and tighten the bolts of the fuel tank bands in the sequence shown in the figure.
    CAUTION: To prevent the fuel tank from damage, after tightening the bolts of the fuel tank bands, make sure that the distance between the end of the reference hole for body and the end of the fuel tank is the following.

    Distance L1 between body reference hole end (A) - Fuel tank end (B): 

    90 mm (3.543 in) - 110 mm (4.331 in)

    Distance L2 between body reference hole end (C) - Fuel tank end (D): 

    140 mm (5.512 in) - 160 mm (6.299 in)

    Distance L3 between body reference hole end (E) - Fuel tank end (F): 

    116 mm (4.576 in) - 136 mm (5.354 in)

    G13198351Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    33 N.m (3.4 kgf-m, 24.3 ft-lb)

    Fig 1: Fuel Tank Band Bolts Tightening Sequence
    G13198352Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the fuel delivery tube to the fuel pipe assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE A) .
    G13198348Courtesy of SUBARU OF AMERICA, INC.
  4. Install the vent tube to the tube clamp.
  5. Connect the vent tube (C) to the canister. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE E) .
  6. Connect the circulate tube (B). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE F) .
  7. Connect the fuel filler hose (A). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>FUEL FILLER HOSE CONNECTION .
    G13198347Courtesy of SUBARU OF AMERICA, INC.
  8. Install the rear differential. Ref. to DIFFERENTIALS>REAR DIFFERENTIAL (VB-TYPE)>INSTALLATION .
  9. Install the rear exhaust pipe and muffler.

    Rear exhaust pipe: 

    Ref. to EXHAUST (H4DOTC)>REAR EXHAUST PIPE>INSTALLATION .

    Muffler: 

    Ref. to EXHAUST (H4DOTC)>MUFFLER>INSTALLATION .

  10. Install the fuel tank protector. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>FUEL TANK PROTECTOR>INSTALLATION .
  11. Lower the vehicle.
  12. Connect the connector to the fuel sub level sensor.
    CAUTION: Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel sub level sensor and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.
    G16438612Courtesy of SUBARU OF AMERICA, INC.
  13. Install the service hole cover LH and refit the floor mat.
    G13198345Courtesy of SUBARU OF AMERICA, INC.
  14. 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.
    G16438610Courtesy of SUBARU OF AMERICA, INC.
  15. Install the service hole cover RH and refit the floor mat.
    G13198343Courtesy of SUBARU OF AMERICA, INC.
  16. Install the second-row seats. Ref. to SEATS>SECOND SEAT>INSTALLATION .
  17. Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
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