Fuel Tank: Service and Repair

FUEL TANK

REMOVAL

1. Set vehicle on the lift.
2. Release fuel pressure.
3. Drain fuel from fuel tank.

4. Remove holder clip which secures fuel tank cord on bracket.

5. Disconnect connector of fuel tank cord to rear harness.

6. Push grommet which holds fuel tank cord on service hole cover into body side.

7. Separate quick connector of fuel delivery (A) and return hose (B).

8. Remove parking brake cable.
1. Remove console box console.
2. Remove parking brake bracket and disconnect parking brake cable from equalizer.

9. Remove trunk trim. (Sedan model)
10. Remove rear quarter lower trim. (Wagon model)

11. Remove pipe protector.

12. Separate quick connector of evaporation pipe (A).
13. Remove wheel nuts from rear wheels.
14. Lift-up the vehicle.
15. Remove rear wheel.

16. Remove front side fuel tank cover.
17. Remove rear exhaust pipe and muffler.

NOTE: To facilitate removal, apply a coat of SUBARU CRC to matching area of rubber cushions in advance.

SUBARU CRC (Part No 004301003)

1. Separate rear exhaust pipe from center exhaust pipe.
2. Remove left and right rubber cushions.

CAUTION: Be careful not to pull down muffler.

3. Remove front rubber cushion and detach muffler assembly.

18. Remove propeller shaft.

19. Disconnect connector from ABS sensor.
20. Remove bolts which hold parking brake cable holding bracket.

21. Remove parking brake cable from cabin by forcibly pulling it backward.

22. Remove bolts which hold parking brake cable holding bracket.

23. Remove bolts which hold rear brake hoses holding bracket.

24. Remove rear brake caliper, then tie it up to the body side of the vehicle as shown in figure. (Rear disk brake model)

25. Disconnect brake pipes from wheel cylinder. (Rear drum brake model)
26. Remove rear suspension assembly.

WARNING: A helper is required to perform this work.

1. Support rear differential with transmission jack.

2. Remove bolt which holds rear shock absorber to rear suspension arm.

3. Remove bolt which secure rear suspension assembly to body.
4. Remove rear suspension assembly.

27. Remove rear side fuel tank cover.

28. Disconnect fuel filler hose (A) and fuel tank pressure sensor (B) hose.

29. Disconnect air vent hose (A) from evaporation pipe assembly and disconnect evaporation hose (I) from pressure control solenoid valve.

30. Support fuel tank with transmission jack1 remove bolts from bands and dismount fuel tank from the vehicle.

WARNING: A helper is required to perform this work.

INSTALLATION

1. Support fuel tank with transmission jack and push fuel tank harness into access hole with grommet.
2. Set fuel tank and temporarily tighten bolts of fuel tank bands.

WARNING: A helper is required to perform this work.

3. Connect air vent hose (A) to evaporation pipe assembly and connect evaporation hose (I) to pressure control solenoid valve.

4. Connect fuel filler hose (A) and fuel tank pressure sensor hose (B).

5. Tighten band mounting bolts.

6. Install rear side fuel tank cover.
7. Install rear suspension assembly.

WARNING: A helper is required to perform this work.

1. Support rear suspension assembly and then tighten bolts which secure rear suspension assembly.

2. Tighten bolt which holds rear shock absorber to rear suspension arm.

8. Connect brake pipes to wheel cylinder. (Rear drum brake model)

9. Install rear brake caliper. (Rear disk brake model)

10. Tighten bolts which hold rear brake hoses holding bracket.
11. Install parking brake cable to cabin by forcibly pushing it forward.

12. Tighten bolts which hold parking brake cable holding bracket.

13. Connect connector to ABS sensor.
14. Install propeller shaft.
15. Install rear exhaust pipe and muffler.

NOTE: To facilitate the procedure, apply a coat of SUBARU CRC to matching area of rubber cushions in advance.

SUBARU CRC (Part No.004301003)

1. Install left and right rubber cushions.

2. Install front rubber cushion and attach muffler assembly.

3. Install rear exhaust pipe to center exhaust pipe.

16. Install front side fuel tank cover.
17. Install rear wheel.
18. Lower the vehicle.
19. Tighten wheel nuts to rear wheel.

20. Install parking brake cable.
21. Install console box.

22. Connect fuel hoses and hold them with quick connector.

23. Connect evaporation pipe (A) and hold it with quick connector.

24. Install pipe protector.
25. Install trunk room trim. (Sedan model)
26. Install luggage room trim. (Wagon model)

27. Connect fuel jet pump hose.

28. Connect connector to fuel sub level sensor.

29. Install sub service hole cover.

30. Connect connectors to fuel tank cord and plug service hole with grommet.

31. Install holder clip which secures fuel tank cord on bracket.
32. Set rear seat and floor mat.

33. Connect connector to fuel pump relay.
34. Bleed air from brake system. (Rear drum brake model only)
35. Adjust parking brake lever stroke.
36. Check wheel alignment and adjust if necessary.