Subaru Legacy IV (2008 year). Service manual - part 41

FU(H4SO)-53

Fuel Filler Pipe

FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

1) Open the fuel filler lid.
2) Set the fuel saucer (A) with rubber gasket (C),
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.

NOTE:
If the edges of rubber seal are folded toward inside,
straighten it with a flat tip screwdriver.

4) Securely insert the fuel filler hose (A) and evap-
oration hose (B) into the specified position, then at-
tach the clamp or clip as shown in the figure.

Tightening torque:

2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

5) Tighten the bolts which hold fuel filler pipe brack-
et on the body.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

6) Install the rear sub frame. <Ref. to RS-21, IN-
STALLATION, Rear Sub Frame.>
7) Install the mud guard. <Ref. to EI-29, INSTAL-
LATION, Mud Guard.>
8) Lower the vehicle.
9) Install the rear wheel RH.

Tightening torque:

120 N·m (12.2 kgf-m, 88.5 ft-lb)

10) Connect the ground cable to battery.

11) Inspect the wheel alignment and adjust if nec-
essary.

FU-00103

(A)

(C)

(B)

(A)

FU-02396

(B)

FU-02397

(B)

(1) Hose

(2) Clamp or clip

(3) Pipe

( 1 )

( 2 )

( 3 )

FU-00104

L

L/2

FU-02395

IN-00203

FU(H4SO)-54

Fuel Filler Pipe

FUEL INJECTION (FUEL SYSTEMS)

C: INSPECTION

1) Check that the fuel tank does not have holes,
cracks or is damaged in any way.
2) Make sure that the fuel hose is not cracked and
that the connections are tight.

D: DISASSEMBLY

1) Move the clip and disconnect the evaporation
hose from the shut valve.

2) Remove the nut which holds the evaporation
pipe assembly to the fuel filler pipe.

3) Remove the shut valve from the fuel filler pipe.
<Ref. to EC(H4SO)-15, REMOVAL, Shut Valve.>

E: ASSEMBLY

1) Install the shut valve to the fuel filler pipe. <Ref.
to EC(H4SO)-15, INSTALLATION, Shut Valve.>
2) Tighten the nuts which secure the evaporation
pipe assembly to the fuel filler pipe.

Tightening torque:

7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

3) Connect the evaporation hose to the shut valve.

FU-02398

 FU-02399

FU-02400

 FU-02399

FU-02400

FU-02398

FU(H4SO)-55

Fuel Pump

FUEL INJECTION (FUEL SYSTEMS)

24.Fuel Pump

A: REMOVAL

WARNING:
Place “NO OPEN FLAMES” signs near the
working area.

CAUTION:
• Be careful not to spill fuel.
• If the fuel gauge indicates that two thirds or
more of the fuel is remaining, be sure to drain
fuel before starting work to avoid the fuel to
spill.

NOTE:
Fuel pump assembly consists of fuel pump, fuel fil-
ter and fuel level sensor.
1) Release the fuel pressure. <Ref. to FU(H4SO)-
43, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
2) Drain fuel. <Ref. to FU(H4SO)-43, DRAINING
FUEL (WITH SUBARU SELECT MONITOR),
PROCEDURE, Fuel.>
3) Disconnect the ground cable from battery.

4) Remove the rear seat.
5) Remove the service hole cover.

(1) Remove the bolt (A).
(2) Push the grommet (B) down and remove the
service hole cover.

6) Disconnect the connector from fuel pump.

7) Disconnect the quick connector of fuel delivery
tube and jet pump tube. <Ref. to FU(H4SO)-65,
REMOVAL, Fuel Delivery and Evaporation Lines.>
8) Remove the nuts which install fuel pump assem-
bly onto fuel tank.

9) Remove the fuel pump assembly from the fuel
tank.

IN-00203

FU-01124

(A)

(B)

(A)

(A) Fuel delivery tube

(B) Jet pump tube

FU-03989

FU-02670

(A)

(B)

FU(H4SO)-56

Fuel Pump

FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

Install in the reverse order of removal while being
careful of the following.
• Make sure the sealing portion is free from fuel or
foreign matter before installation.
• Install with the protrusion (A) of gasket aimed at
the front side of the vehicle.
• Insert the protrusion (B) of the gasket into the up-
per plate. (3 places)
• Align the protrusion (C) of the fuel pump assem-
bly to the cutout in the upper plate.
• Tighten the nuts to the specified torque in the or-
der as shown in the figure.

NOTE:
Use a new gasket and retainer.

Tightening torque:

4.4 N·m (0.4 kgf-m, 3.2 ft-lb)

C: INSPECTION

Connect the lead harness to the connector terminal
of fuel pump, and apply the battery power supply to
check whether the pump operates.

WARNING:
• Wipe off fuel completely.
• Keep the battery as far apart from fuel pump
as possible.
• Be sure to perform the ON/OFF operation on
the battery side.
• Do not run the fuel pump for a long time un-
der non-load condition.

1

2

3

4

5

6

7

8

(C)

(B)

(B)

(B)

(A)

FU-02835

FU-01330

2
4
6

1
3
5