Fuel Tank: Service and Repair
REMOVAL1. Release fuel pressure.
2. Open fuel flap lid, and remove fuel filler cap.
3. Disconnect battery ground cable.
4. Drain fuel from fuel tank.
5. Remove rear seat cushion. (Sedan model)
6. Move rear seat cushion forward. (Wagon model)
7. Disconnect connector of fuel tank cord from rear harness.
8. Push grommet which holds fuel tank cord on floor panel into under the body.
9. Lift-up the vehicle.
10. Remove rear exhaust pipe.
1. Separate rear exhaust pipe from center exhaust pipe.
2. Separate rear exhaust pipe from muffler.
3. Remove bracket from rubber cushion, and remove exhaust pipe.
NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC5-56 (Part No.004301003).
11. Remove heat sealed cover.
12. Remove muffler assembly.
NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC5-56 (Part No.004301003).
13. Loosen clamp, and disconnect evaporation hose from canister.
14. Loosen clamp, disconnect hose from joint pipe.
15. Disconnect connector from pressure control solenoid valve.
16. Disconnect connector from drain valve.
17. Disconnect hoses from roll over valve.
18. Remove bolts which hold parking brake cable holding bracket.
19. Remove rear differential assembly.
1. Remove rear axle shafts from rear differential assembly.
2. Remove rear differential front cover.
3. Remove propeller shaft.
4. Remove lower differential bracket.
5. Set transmission jack under rear differential.
6. Remove bolts which install rear differential onto rear crossmember.
20. Remove rear crossmember.
21. Remove two evaporation hoses from holding clip.
22. Loosen clamp, and disconnect fuel filler hose.
23. Loosen clamp, and then disconnect fuel delivery hose (A).
24. Move clips, and disconnect fuel return hose (B) and evaporation hose (C).
25. While holding fuel tank, remove bolts from bands and dismount fuel tank.
WARNING: A HELPER IS REQUIRED TO PERFORM THIS WORK.
INSTALLATION
1. While a helper holds fuel tank, push fuel tank harness into access hole with grommet.
2. Set fuel tank, and temporary tighten bolts for installing fuel tank bands.
3. Connect fuel filler hose, and tighten clamp.
4. Install two evaporation hoses to holding clip.
5. Install hose and hold down clips at positions indicated.
Tightening torque:
1.0 (+0.5/-0) Nm (0.1 (+0.05/-0) kg.m, 0.7 (+0.4/-0) ft.lb)
Type A: When fitting length is specified.
Type B: When fitting length is not specified.
l: 1.0 - 4.0 mm (0.039 - 0.157 in)
L: 20 - 25 mm (0.79 - 0.98 in)
Fuel return hose:
L = 20 - 25 mm (0.79 - 0.98 in)
Evaporation hose:
L = 15 - 20 mm (0.59 - 0.79 in)
6. Tighten band mounting bolts.
Tightening torque:
33 ± 10 Nm (3.4 ± 1.0 kg.m, 25 ± 7 ft.lb)
7. Install rear crossmember.
8. Install rear differential assembly.
9. Connect connector to drain valve.
10. Connect connector to pressure control solenoid valve.
11. Connect hose to joint pipe, and tighten them with clamp.
12. Connect evaporation hose to canister, and tighten them with clamp.
13. Connect hoses to roll over valve.
14. Install muffler assembly.
15. Install heat sealed cover.
16. Install bolts which hold parking brake holding bracket.
17. Install rear exhaust pipe.
18. Lower the vehicle.
19. Connect connectors to fuel tank harness, and plug access hole with grommet.
20. Install rear seat cushion. (Sedan model)
21. Set rear seat cushion. (Wagon model)
22. Install fuel filler cap.
23. Install fuel pump, and connect connector and fuel hoses.
24. Install fuel sub meter unit, and connect connector and jet pump hose.
25. Connect battery ground cable.