2016 Subaru WRX STI Series.HyperBlueFACTORY OEM SERVICE PROCEDURE

Fuel Sub Level Sensor: Installation

  1. Install the fuel sub level sensor to the fuel tank.
    1. Make sure the sealing portion is free from fuel or foreign matter before installation.
    2. Align the cutout (B) as shown in the figure, and install the fuel sub level sensor upper plate cushion to the fuel sub level sensor upper plate.
    3. Align the cutout of the fuel sub level sensor upper plate with the protrusion (B) of the fuel sub level sensor as shown in the figure, and install the fuel sub level sensor upper plate from the upper side of the fuel sub level sensor.
    4. Install the gasket from the lower side of the fuel sub level sensor so that the protrusion (B) of the fuel sub level sensor and the protrusion (A) of the gasket are positioned as shown in the figure.
      NOTE: Use a new gasket.
    5. Install the fuel sub level sensor to the fuel tank in the direction shown in the figure, and tighten the nuts to the specified torque in the order as shown in the figure.
      CAUTION: Set the arm and float of the fuel sub level sensor while paying attention to prevent them from contacting the fuel tank. If the arm of the fuel sub level sensor is bent, the fuel gauge may not read correctly.

      Tightening torque: 

      4.4 N.m (0.4 kgf-m, 3.2 ft-lb) 

      Fig 1: Fuel Sub Level Sensor Upper Plate Bolts Tightening Sequence
      G10289971Courtesy of SUBARU OF AMERICA, INC.
  2. Install the bolt which secures the fuel sub level sensor protector to the fuel tank.

    Tightening torque: 

    4.4 N.m (0.4 kgf-m, 3.2 ft-lb) 

    Fig 2: Locating Fuel Sub Level Sensor Protector Bolts And Nuts
    G10264946Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the quick connectors of fuel delivery tube (A), fuel return tube (B), and jet pump tube (C). < Ref. to INSTALLATION , Fuel Delivery, Return and Evaporation Lines. >
  4. Attach the rubber cap (D) to the nut.
    Fig 3: Identifying Fuel Delivery, Fuel Return And Jet Pump Tube
    G10264945Courtesy of SUBARU OF AMERICA, INC.
  5. Connect the connector to the fuel sub level sensor.
    Fig 4: Locating Fuel Sub Level Sensor Connector
    G10264944Courtesy of SUBARU OF AMERICA, INC.
  6. Install the service hole cover.
    Fig 5: Locating Service Hole Cover Bolts
    G10264943Courtesy of SUBARU OF AMERICA, INC.
  7. Install the rear seat cushion. < Ref. to INSTALLATION , Rear Seat. >
  8. Connect the battery ground terminal.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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