Fuel Tank Removal and Installation

REMOVAL

WARNING:
- Place "NO FIRE" signs near the working area.
- Be careful not to spill fuel on the floor.

1. Set the vehicle on the lift.




2. Drain fuel from fuel tank.




3. Remove rear seat cushion and turn up cover.




4. Disconnect connector of fuel tank cord from rear harness.




5. Push grommet which holds fuel tank cord on floor panel into the body side.
6. Lift-up the vehicle.




7. Remove rear exhaust pipe.

NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC5-56 (Part No.004301003).




8. Remove muffler assembly.

NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC5-56 (Part No.004301003).




9. Remove heat sealed cover.




10. Move clamp, and disconnect evaporation hose from canister.




11. Disconnect hose from joint pipe.
12. Disconnect connector from pressure control solenoid valve.




13. Disconnect connector from drain valve.




14. Disconnect hoses from roll over valve.




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




16. Remove rear differential assembly.




17. Remove rear crossmember.




18. Loosen clamp, and disconnect fuel filler hose (A) and air vent hose (B) from fuel filler pipe and air vent pipe.
19. Move clips, and disconnect fuel return hose (B) and evaporation hose (C).




20. Disconnect quick connector, and then disconnect fuel delivery hose (A).




21. 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 in order to install fuel tank bands.




3. Connect fuel tiller hose, and tighten clamp.
4. Connect fuel hoses, and hold then with clips and quick connector.




5. Tighten band mounting bolts.




6. Install rear crossmember.




7. Install rear differential assembly.




8. Connect connector to drain valve.
9. Connect connector to pressure control solenoid valve.




10. Connect hose to joint pipe.




11. Connect evaporation hose to canister, and hold them with clamp.




12. Connect hoses to roll over valve.




13. Install bolts which hold parking brake holding bracket.




14. Install heat sealed cover.




15. Install muffler assembly.




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.