fuel tank removal SUBARU LEGACY 1997 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 1997, Model line: LEGACY, Model: SUBARU LEGACY 1997Pages: 3342, PDF Size: 62.95 MB
Page 237 of 3342
B2M0955A
B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent fuel from flowing out through fuel delivery and
return pipes. Close fuel filler cap after tightening nuts.
Installation is in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
G6M0095
9. Fuel Tank Pressure Sensor (2200 cc
AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
H2M1122B
2) Remove trims.
4 door model:
Remove right trunk side trim.
B2M0927A
Wagon model:
(1) Remove right rear quarter upper rear trim.
(2) Remove right strut cap.
(3) Remove right rear quarter pillar lower trim.
11
2-1SERVICE PROCEDURE
8. Fuel Temperature Sensor (2200 cc AWD Model) - 9. Fuel Tank Pressure Sensor (2200 cc AWD Model)
Page 238 of 3342
B2M0955A
B: INSTALLATION
CAUTION:
Leave fuel filler cap open when tightening nuts, to pre-
vent fuel from flowing out through fuel delivery and
return pipes. Close fuel filler cap after tightening nuts.
Installation is in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign
particles before installation.
(3) Tighten nuts in numerical sequence shown in Fig-
ure to specified torque.
Tightening torque:
4.4±1.5 N⋅m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
G6M0095
9. Fuel Tank Pressure Sensor (2200 cc
AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
H2M1122B
2) Remove trims.
4 door model:
Remove right trunk side trim.
B2M0927A
Wagon model:
(1) Remove right rear quarter upper rear trim.
(2) Remove right strut cap.
(3) Remove right rear quarter pillar lower trim.
11
2-1SERVICE PROCEDURE
8. Fuel Temperature Sensor (2200 cc AWD Model) - 9. Fuel Tank Pressure Sensor (2200 cc AWD Model)
Page 239 of 3342
B2M0960
3) Disconnect connector from fuel tank pressure sensor.
4) Remove bolts which install fuel tank pressure sensor
bracket on body.
B2M0961
5) Disconnect hose from fuel tank pressure sensor.
6) Remove fuel tank pressure sensor from bracket.
7) Installation is in the reverse order of removal.
G6M0095
10. Pressure Control Solenoid Valve
(2200 cc AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
2) Lift-up the vehicle.
B2M0962
3) Disconnect evaporation hoses from pressure control
valve.
4) Disconnect connector from pressure control valve.
B2M0963
5) Remove pressure control valve from bracket.
6) Installation is in the reverse order of removal.
12
2-1SERVICE PROCEDURE
9. Fuel Tank Pressure Sensor (2200 cc AWD Model) - 10. Pressure Control Solenoid Valve (2200 cc AWD Model)
Page 240 of 3342
B2M0960
3) Disconnect connector from fuel tank pressure sensor.
4) Remove bolts which install fuel tank pressure sensor
bracket on body.
B2M0961
5) Disconnect hose from fuel tank pressure sensor.
6) Remove fuel tank pressure sensor from bracket.
7) Installation is in the reverse order of removal.
G6M0095
10. Pressure Control Solenoid Valve
(2200 cc AWD Model)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
2) Lift-up the vehicle.
B2M0962
3) Disconnect evaporation hoses from pressure control
valve.
4) Disconnect connector from pressure control valve.
B2M0963
5) Remove pressure control valve from bracket.
6) Installation is in the reverse order of removal.
12
2-1SERVICE PROCEDURE
9. Fuel Tank Pressure Sensor (2200 cc AWD Model) - 10. Pressure Control Solenoid Valve (2200 cc AWD Model)
Page 243 of 3342
![SUBARU LEGACY 1997 Service Repair Manual G6M0095
12. Fuel Level Sensor (2200 cc AWD
Model)
A: REMOVAL
1) Disconnect battery ground cable.
B2M0954A
2) Release fuel pressure. <Ref. to 2-8 [W1A0].>
3) Disconnect fuel delivery hose
1, return ho](/img/17/57434/w960_57434-242.png "SUBARU LEGACY 1997 Service Repair Manual G6M0095
12. Fuel Level Sensor (2200 cc AWD
Model)
A: REMOVAL
1) Disconnect battery ground cable.
B2M0954A
2) Release fuel pressure. <Ref. to 2-8 [W1A0].>
3) Disconnect fuel delivery hose
1, return ho")
G6M0095
12. Fuel Level Sensor (2200 cc AWD
Model)
A: REMOVAL
1) Disconnect battery ground cable.
B2M0954A
2) Release fuel pressure.
3) Disconnect fuel delivery hose
1, return hose2and jet
pump hose
3.
B2M0955
4) Remove nuts which install fuel pump assembly onto
fuel tank.
B2M0956
5) Take off fuel pump assembly from fuel tank.
H2M1459
6) Disconnect connector from fuel pump.
15
2-1SERVICE PROCEDURE
12. Fuel Level Sensor (2200 cc AWD Model)
Page 534 of 3342
![SUBARU LEGACY 1997 Service Repair Manual G2M0345
3. Fuel Tank
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>
G2M0382
3) Remove rear exhaust pipe.
(1) Lift-up the vehicle.
(2) Se](/img/17/57434/w960_57434-533.png "SUBARU LEGACY 1997 Service Repair Manual G2M0345
3. Fuel Tank
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>
G2M0382
3) Remove rear exhaust pipe.
(1) Lift-up the vehicle.
(2) Se")
G2M0345
3. Fuel Tank
A: REMOVAL
1) Release fuel pressure.
2) Drain fuel from fuel tank.
G2M0382
3) Remove rear exhaust pipe.
(1) Lift-up the vehicle.
(2) Separate rear exhaust pipe from center exhaust
pipe.
(3) Separate rear exhaust pipe from muffler.
(4) Remove bracket from rubber cushion, and remove
exhaust pipe.
NOTE:
To facilitate the removal of parts, apply a coat of SUBARU
CRC5-56 (Part No. 004301003)
G2M0384
4) Remove muffler assembly.
NOTE:
To facilitate the removal of parts, apply a coat of SUBARU
CRC5-56 (Part No. 004301003)
G3M0059
5) Remove rear differential assembly. (AWD model)
(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.
13
2-8SERVICE PROCEDURE
3. Fuel Tank
Page 535 of 3342
![SUBARU LEGACY 1997 Service Repair Manual G4M0545
6) Remove rear crossmember. (AWD model)
<Ref. to 4-1 [W11A0].>
G2M0353
7) Loosen clamp, and disconnect fuel filler hose from pipe.
8) Loosen clamp, and disconnect air vent hose from air
vent p](/img/17/57434/w960_57434-534.png "SUBARU LEGACY 1997 Service Repair Manual G4M0545
6) Remove rear crossmember. (AWD model)
<Ref. to 4-1 [W11A0].>
G2M0353
7) Loosen clamp, and disconnect fuel filler hose from pipe.
8) Loosen clamp, and disconnect air vent hose from air
vent p")
G4M0545
6) Remove rear crossmember. (AWD model)
G2M0353
7) Loosen clamp, and disconnect fuel filler hose from pipe.
8) Loosen clamp, and disconnect air vent hose from air
vent pipe.
1Fuel filler hose
2Air vent hose
B2M0310A
9) Loosen clip and clamps, and disconnect fuel delivery
hose
1, return hose2and evaporation hose3.
G2M0356
10) While holding fuel tank, remove bolts from bands and
dismount fuel tank.
WARNING:
A helper is required to perform step 10).
B: INSTALLATION
Installation is in the reverse order of removal. Do the fol-
lowing:
1) When installing fuel tank, have a helper hold fuel tank
while installing bands.
2) Before tightening band mounting bolts, connect fuel
system hoses.
14
2-8SERVICE PROCEDURE
3. Fuel Tank
Page 537 of 3342
![SUBARU LEGACY 1997 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi](/img/17/57434/w960_57434-536.png "SUBARU LEGACY 1997 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi")
G3M0059
6) Install rear differential assembly.
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehicle, and connect connector to fuel
pump.
11) Install access hole lid.
G2M0345
4. Fuel Filler Pipe
A: REMOVAL
1) Release fuel pressure.
2) Drain fuel from fuel tank.
16
2-8SERVICE PROCEDURE
3. Fuel Tank - 4. Fuel Filler Pipe
Page 538 of 3342
![SUBARU LEGACY 1997 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi](/img/17/57434/w960_57434-537.png "SUBARU LEGACY 1997 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi")
G3M0059
6) Install rear differential assembly.
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehicle, and connect connector to fuel
pump.
11) Install access hole lid.
G2M0345
4. Fuel Filler Pipe
A: REMOVAL
1) Release fuel pressure.
2) Drain fuel from fuel tank.
16
2-8SERVICE PROCEDURE
3. Fuel Tank - 4. Fuel Filler Pipe
Page 542 of 3342
C: INSTALLATION
CAUTION:
If fuel hoses are damaged at the connecting portion,
replace it with a new one.
If clamps are badly damaged, replace with new ones.
G2M0347
1) Installation is in the reverse order of removal.
2) Tighten hose clamp screws.
Tightening torque:
1.0
+0.5
0N⋅m (0.1+0.05
0kg-m, 0.7+0.4
0ft-lb)
B2M0048A
6. Fuel Pump
A: REMOVAL
1) Release fuel pressure.
2) Disconnect fuel delivery hose
1and return hose2.
3) Disconnect jet pump hose
3. (AWD model)
G2M0343
4) Remove nuts which install fuel pump assembly onto
fuel tank.
G2M0344
5) Take off fuel pump from fuel tank.
19
2-8SERVICE PROCEDURE
5. Fuel Filter - 6. Fuel Pump