Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



Justy

See Figures 1, 2 and 3

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Fig. Fig. 1: Fuel tank assembly-Justy with carbureted engine



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Fig. Fig. 2: Fuel tank assembly-3-door Justy with fuel injection



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Fig. Fig. 3: Fuel tank assembly-5-door Justy with fuel injection

  1. Disconnect the negative battery cable.
  2.  
  3. Release the fuel system pressure, if equipped with fuel injection.
  4.  
  5. Drain any fuel from the tank into a suitable container. Observe all fire precautions.
  6.  
  7. Remove the rear seat back and lower cushion assemblies.
  8.  
  9. Remove the left side sill trim, then remove the filler pipe cover.
  10.  
  11. Remove the separator and roll-over valve, and disconnect the tube from the separator by moving the clip out of place.
  12.  
  13. Remove the access hole plate, and disconnect the electrical harness from the sender unit.
  14.  
  15. Disconnect the fuel filler hose from the fuel tank.
  16.  
  17. Disconnect the air vent hose from the filler pipe.
  18.  
  19. Raise and safely support the vehicle on jackstands.
  20.  
  21. Remove the two parking brake cable mounting bolts and lower the cable assembly.
  22.  
  23. Remove the fuel filter bracket mounting bolts.
  24.  
  25. Disconnect and cap the fuel lines from the tank-to-fuel filter and fuel tank-to-return pipe.
  26.  
  27. Support the tank with a suitable jack.
  28.  
  29. Remove the six tank mounting bolts and lower the tank from the vehicle.
  30.  

To install:
  1. Raise the fuel tank into position and install the six mounting bolts. Tighten the mounting bolts to 13 ft. lbs. (18 Nm).
  2.  
  3. Connect the fuel lines from the fuel filter-to-fuel tank and the fuel tank-to-return pipe.
  4.  
  5. Position the fuel filter bracket and install the mounting bolts.
  6.  
  7. Position the parking brake cable assembly and install the mounting bolts.
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the air vent hose to the filler neck.
  12.  
  13. Connect the fuel filler hose to the tank.
  14.  
  15. Connect the electrical harness to the sender unit and install the access plate.
  16.  
  17. Install the separator and roll-over valve, and connect the tube to the separator with the clip.
  18.  
  19. Install the filler pipe cover and install the left side sill trim.
  20.  
  21. Install the rear seat back and lower cushion.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Start the vehicle and check for leaks.
  26.  

Coupe, XT, Sedan, Wagon, Loyale and Brat

See Figure 4

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Fig. Fig. 4: Fuel tank assembly-Coupe, XT, Sedan, Wagon, Loyale and Brat

  1. Release the fuel system pressure, if equipped with fuel injection.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle on jackstands.
  6.  
  7. Remove the muffler and differential assembly, if equipped with 4WD.
  8.  
  9. Remove the fuel filler cap and drain the fuel tank into a suitable container.
  10.  
  11. Remove the fuel filler pipe protector.
  12.  
  13. Remove the clamp and disconnect the fuel filler hose from the filler pipe.
  14.  
  15. Remove the clamp and disconnect the vent hose from the vent pipe.
  16.  
  17. Loosen the clamps and disconnect the fuel delivery, return and vent hoses from the tank sender unit.
  18.  
  19. Support the tank with a suitable jack and remove the tank mounting bolts.
  20.  
  21. Lower the tank slightly and unfasten the electrical connector from the fuel sender.
  22.  
  23. Remove the tank from the vehicle.
  24.  

To install:
  1. Raise the tank into position, fasten the electrical harness to the sender and install the six mounting bolts.
  2.  
  3. Connect the fuel delivery, return and vent hoses to the sender assembly, then tighten the clamps.
  4.  
  5. Connect the fuel filler and vent hoses and tighten the clamps.
  6.  
  7. Install the fuel filler pipe protector.
  8.  
  9. Install the differential carrier and muffler, if removed.
  10.  
  11. Lower the vehicle.
  12.  
  13. Refill the fuel system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the vehicle and check for leaks.
  18.  

Impreza and Legacy

See Figures 5 and 6

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Fig. Fig. 5: Fuel tank assembly- FWD Impreza and Legacy



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Fig. Fig. 6: Fuel tank assembly- AWD Impreza and Legacy


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the rear exhaust pipe and muffler assembly.
  6.  
  7. On All Wheel Drive (AWD) vehicles, remove the rear differential assembly and the rear crossmember.
  8.  
  9. Remove the fuel filler cap and drain the fuel into a suitable container.
  10.  
  11. Remove the fuel filler pipe protector.
  12.  
  13. Raise and support the vehicle safely on jackstands.
  14.  
  15. Remove the fuel filler, air vent and delivery hoses.
  16.  
  17. On AWD vehicles, disconnect the air breather hoses and evaporation hose from the pipes.
  18.  
  19. Support the fuel tank with a floor jack or equivalent lifting device.
  20.  
  21. Loosen the attaching bolts and lower the fuel tank slightly.
  22.  
  23. Disconnect the fuel pump harness and, if equipped with AWD, disconnect the fuel meter connector.
  24.  

To install:
  1. Connect the pump harness.
  2.  
  3. Raise the fuel tank into position and install the attaching bolts. Tighten the bolts to 9-17 ft. lbs. (13-23 Nm).
  4.  

Ensure that the hoses and connectors are not pinched.

  1. On AWD vehicles, connect the air breather and evaporation hoses.
  2.  
  3. Connect the fuel filler, air vent and delivery hoses.
  4.  
  5. Install the fuel filler pipe protector.
  6.  
  7. Install the fuel filler cap.
  8.  
  9. On AWD vehicles, install the crossmember and rear differential assembly.
  10.  
  11. Install the rear muffler assembly and exhaust pipe.
  12.  
  13. Lower the vehicle.
  14.  
  15. Fill the fuel tank with gasoline.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the vehicle and check for leaks.
  20.  

SVX

See Figure 7

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Fig. Fig. 7: Fuel tank assembly- SVX


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Properly release the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the fuel hose and air vent hose. Remove the fuel tank cap using special tool 42911PA000 or equivalent.
  6.  
  7. Properly drain the fuel from the tank into a suitable container.
  8.  
  9. Install the fuel tank cap.
  10.  
  11. Unfasten the fuel tank electrical connector.
  12.  
  13. Raise and safely support the vehicle on jackstands.
  14.  
  15. Remove the rear exhaust pipe and muffler assembly.
  16.  
  17. Separate the rear axle shaft from the rear differential assembly.
  18.  
  19. Remove the propeller shaft and the rear differential assembly.
  20.  
  21. Remove the rear subframe.
  22.  
  23. Separate the fuel filler duct from the pipe.
  24.  
  25. Disconnect the fuel delivery, return and evaporative hoses from each pipe.
  26.  
  27. Place a floor jack under the fuel tank to support it while removing it.
  28.  
  29. While supporting the fuel tank, remove the bolts from the bands and lower the fuel tank slowly.
  30.  

To install:
  1. Position the fuel tank to the vehicle and install the band retaining bolts snugly.
  2.  
  3. Connect the fuel hoses.
  4.  
  5. Tighten the band mounting bolts to 17-31 ft. lbs. (23-42 Nm).
  6.  
  7. Connect the fuel filler pipe to the fuel filler duct.
  8.  
  9. Install the rear subframe.
  10.  
  11. Install the rear differential assembly and the propeller shaft.
  12.  
  13. Install the rear axle shaft to the rear differential assembly.
  14.  
  15. Install the muffler and rear exhaust pipe assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. Fasten the fuel tank electrical connector.
  20.  
  21. Connect the fuel hose and air vent hose.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Fill the tank with fuel, start the vehicle and check for leaks.
  26.  

SENDING UNIT REPLACEMENT



Without In-Tank Fuel Pump
1.8L, 2.2L, 2.5L AND 2.7L ENGINES
  1. Release the fuel system pressure.
  2.  
  3. Remove the mat from the trunk floor.
  4.  
  5. Remove the access hole lid and disconnect the wiring harness.
  6.  
  7. Loosen the sending unit nuts and remove.
  8.  

To install:
  1. Install the sending unit and tighten the nuts to 16-28 inch lbs. (2-3 Nm) in a star pattern.
  2.  
  3. Connect the wiring harness and install the access hole lid.
  4.  
  5. Install the trunk floor mat.
  6.  

With In-Tank Fuel Pump
1.2L MFI AND 3.3L ENGINES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rear seat back and bottom cushion.
  4.  
  5. Remove the fuel sender access hole cover plate.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Disconnect the electrical harness from the fuel pump.
  10.  
  11. Disconnect and cap the fuel lines from the fuel sender assembly.
  12.  
  13. Remove the eight screws securing the fuel pump assembly into the fuel tank.
  14.  
  15. Remove the fuel sender from the pump assembly.
  16.  

To install:
  1. Connect the fuel lines to the pump, then install the fuel sender on the pump assembly.
  2.  
  3. Connect the electrical harness to the fuel pump.
  4.  
  5. Install the fuel pump assembly in the fuel tank and install the eight mounting screws.
  6.  
  7. Connect the fuel lines to the fuel sender.
  8.  
  9. Connect the electrical harness to the fuel sender.
  10.  
  11. Install the fuel sender access hole cover.
  12.  
  13. Install the rear seat bottom and back.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the vehicle and check for leaks.
  18.  

 
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