Fuel Tank: Service and Repair
FUEL TANKA: REMOVAL
1) Release fuel pressure.
2) Disconnect battery ground cable.
3) Drain fuel from fuel tank.
4) Remove rear seat cushion, and turn up cover.
5) Disconnect connector of fuel tank cord from rear harness.
6) Push grommet which holds fuel tank cord on floor panel into under the body.
7) Remove fuel filler cap.
8) Lift-up the vehicle.
9) 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 ORG5-56 (Part No. 004301003)
10) Remove heat sealed cover.
11) Remove muffler assembly.
NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC5-56 (Part No. 004301003)
12) Disconnect connector from vent control solenoid valve.
13) Remove clip, and disconnect evaporation hose from canister.
14) Disconnect hoses from pressure control solenoid valve.
15) Disconnect connector of pressure control solenoid valve.
16) Disconnect hoses from roll over valve.
17) Remove bolts which hold parking brake cable holding bracket.
18) 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.
19) Remove rear crossmember.
20) Loosen clamp, and disconnect fuel filler hose (A) and air vent hose (B) from fuel filler pipe and air vent pipe.
21) Move clips, and disconnect fuel return hose (B) and evaporation hose (C).
22) Disconnect quick connector, and then disconnect fuel delivery hose (A).
23) While holding fuel tank, remove bolts from bands and dismount fuel tank.
WARNING: A helper is required to perform this work.
B: 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 (A) and air vent hose (B).
4) Connect fuel hoses, and hold them with clips and quick connector.
5) Tighten band mounting bolts.
Tightening torque: 33 ± 10 N.m (3.4 ± 1.0 kg-m, 25 ± 7 ft-lb)
6) Install rear crossmember.
7) Install rear differential assembly.
8) Connect connector to vent control solenoid valve.
9) Connect evaporation hose to canister, and hold them with clip.
10) Connect connector to pressure control solenoid valve.
11) Connect hoses to pressure control solenoid valve.
12) Connect hoses to roll over valve.
13) Install muffler assembly.
14) Install heat sealed cover.
15) Install bolts which hold parking brake holding bracket.
16) Install rear exhaust pipe.
17) Lower the vehicle.
18) Connect connectors to fuel tank harness, and plug access hole with grommet.
19) Install rear seat cushion.
20) Install fuel filler cap.
21) Connect connector to fuel pump relay.
22) Connect battery ground cable.