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Home >> Subaru >> 2009 >> Impreza WRX STi >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (STI) >> Fuel Tank >> Installation

Fuel Tank: Installation

  1. Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band.
    WARNING: A helper is required to perform this work.
    Fig 1: Locating Fuel Tank Band Bolts
    G05659517Courtesy of SUBARU OF AMERICA, INC.
  2. Securely insert the fuel filler hose (A) and evaporation hose (B) into the specified position, then attach the clamp or clip as shown in the figure.

    Tightening torque: 2.5 N.m (0.3 kgf-m, 1.8 ft-lb) 

    Fig 2: Disconnecting Fuel Filler Hose And Evaporation Hose
    G05659516Courtesy of SUBARU OF AMERICA, INC.
    Fig 3: Identifying Fuel Filler Hose And Evaporation Hose Clamping Position
    G06344779Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the quick connector of the evaporation hose to the evaporation pipe.
    CAUTION:
    • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
    • When connecting the quick connector, securely insert the pipe all the way before locking the retainer.
    • When it is difficult to lock the retainer, make sure that the pipe is securely inserted.
    • Make sure that the quick connector is securely connected.
      Fig 4: Connecting Quick Connector Of Evaporation Hose To Evaporation Pipe (1 Of 2)
      G06344780Courtesy of SUBARU OF AMERICA, INC.
      Fig 5: Connecting Quick Connector Of Evaporation Hose To Evaporation Pipe (2 Of 2)
      G05659515Courtesy of SUBARU OF AMERICA, INC.
  4. Connect evaporation hose (B) to connector (A).
    Fig 6: Identifying Evaporation Hose And Connector
    G05659513Courtesy of SUBARU OF AMERICA, INC.
  5. Tighten the bolts of the fuel tank band in the order shown in the figure.

    Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb) 

    Fig 7: Locating Fuel Tank Band Bolts
    G05954897Courtesy of SUBARU OF AMERICA, INC.
  6. Install the rear suspension assembly.
    WARNING: A helper is required to perform this work.
    1. Support the rear differential with the transmission jack.
    2. Support the rear suspension assembly and install the rear suspension assembly to the body.

      Tightening torque: 

      T1: 70 N.m (7.1 kgf-m, 51.6 ft-lb) 

      T2: 145 N.m (14.8 kgf-m, 106.9 ft-lb) 

      Fig 8: Identifying Rear Suspension Assembly
      G06344784Courtesy of SUBARU OF AMERICA, INC.
    3. Install the rear shock absorber to the rear suspension arm.
      NOTE: Use a new self-locking nut.

      Tightening torque: 120 N.m (12.2 kgf-m, 88.5 ft-lb) 

      Fig 9: Identifying Rear Suspension Bolt And Nut
      G05659511Courtesy of SUBARU OF AMERICA, INC.
  7. Connect canister drain hose (B) to canister drain connector (A).
    Fig 10: Identifying Canister Drain Hose And Canister Drain Connector
    G05659510Courtesy of SUBARU OF AMERICA, INC.
  8. Install the parking brake cable clamp to the body.

    Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) 

    Fig 11: Locating Parking Brake Cable Clamp
    G05659509Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the connector to the rear ABS wheel speed sensor.
    Fig 12: Locating Rear ABS Wheel Speed Sensor Connector
    G05659508Courtesy of SUBARU OF AMERICA, INC.
  10. Install the heat shield cover.

    Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) 

  11. Install the fuel tank protector.

    Tightening torque: 

    Nut: 9 N.m (0.9 kgf-m, 6.6 ft-lb) 

    Bolt: 18 N.m (1.8 kgf-m, 13.3 ft-lb) 

  12. Install the propeller shaft. Ref. to INSTALLATION , Propeller Shaft.
  13. Install the rear exhaust pipe and muffler. Ref. to INSTALLATION , Rear Exhaust Pipe. Ref. to INSTALLATION , Muffler.
  14. Lower the vehicle.
  15. Connect the parking brake cable to the parking brake assembly. Ref. to INSTALLATION , Parking Brake Assembly (Rear Disc Brake).
  16. Install the rear disc brake assembly.

    Tightening torque: 65 N.m (6.6 kgf-m, 47.9 ft-lb) 

    Fig 13: Locating Rear Disc Brake Assembly Bolts
    G06344789Courtesy of SUBARU OF AMERICA, INC.
  17. Install the rear brake hose bracket to the rear housing.

    Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb) 

    Fig 14: Locating Rear Brake Hose Bracket
    G06344765Courtesy of SUBARU OF AMERICA, INC.
  18. Attach the rear ABS wheel speed sensor to the rear housing.

    Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb) 

    Fig 15: Locating Rear ABS Wheel Speed Sensor
    G05659505Courtesy of SUBARU OF AMERICA, INC.
  19. Install the rear wheels.

    Tightening torque: 100 N.m (10.2 kgf-m, 73.8 ft-lb) 

  20. Connect the quick connector of fuel delivery tube (A) and fuel return tube (B). Ref. to INSTALLATION , Fuel Delivery, Return and Evaporation Lines.
    NOTE: When connecting, be careful not to reverse the delivery side and return side.
    Fig 16: Identifying Quick Connector Of Fuel Delivery Tube And Fuel Return Tube
    G05660535Courtesy of SUBARU OF AMERICA, INC.
  21. Install the service hole cover of fuel sub level sensor.
    Fig 17: Locating Service Hole Cover Of Fuel Sub Level Sensor And Screws
    G05660534Courtesy of SUBARU OF AMERICA, INC.
  22. Attach the service hole cover of the fuel pump, and attach the connector and clip.
    Fig 18: Identifying Service Hole Cover Of Fuel Pump With Connector And Clip
    G06344794Courtesy of SUBARU OF AMERICA, INC.
  23. Install the rear seat cushion. Ref. to INSTALLATION , Rear Seat.
  24. Connect the ground cable to battery.
    Fig 19: Identifying Battery Ground Cable
    G05019586Courtesy of SUBARU OF AMERICA, INC.
  25. Inspect the wheel alignment and adjust if necessary.