Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2024 Subaru Outback BaseFACTORY OEM SERVICE PROCEDURE
Fuel Sub Level Sensor: Installation
- Install a new gasket to the fuel tank.
- Install the fuel sub delivery tube to the fuel sub level sensor.
- Set the fuel sub level sensor to the position shown in the figure.CAUTION:
- Be careful not to spill any fuel over the gasket. If any fuel is spilled onto the gasket, wipe it off completely. Otherwise the fuel sub level sensor may rotate together with the ring nut.
- Set the fuel sub level sensor while paying attention to prevent its arm and float from contacting the fuel tank. If the arm of the fuel sub level sensor is bent, the fuel gauge may not read correctly.
(a) Position mark (fuel sub level sensor) (b) Fuel sub level sensor installation position range mark (fuel tank) (c) Front side of vehicle - Set a new ring nut plate.
- Set a new ring nut, and align the fuel tank installation start position mark with the ring nut position mark.NOTE:
- Make sure that the ring nut, ring nut plate and gasket are set as shown in the figure.
- Set the ring nut by firmly pressing against the fuel tank.
(a) Installation start position mark (fuel tank) (b) Position mark (ring nut) (c) Ring nut (d) Ring nut plate (e) Gasket - Using the ST, tighten the ring nut by one turn, and then tighten until the ring nut position mark is located within the installation end position range mark on the fuel tank.CAUTION:
- Make sure that the ring nut position mark is located within the installation position end range mark on the fuel tank as shown in the figure.
- Make sure that the position mark on the fuel sub level sensor is located within the installation position range mark on the fuel tank as shown in the figure.
Preparation tool:
ST: ST FUEL PUMP (42099FL000)
(a) Ring nut installation position start mark (fuel tank) (b) Position mark (ring nut) (c) Ring nut installation position end range mark (fuel tank) (d) Fuel sub level sensor installation position range mark (fuel tank) (e) Position mark (fuel sub level sensor) (f) Front side of vehicle - Using a caliper with depth gauge, measure the dimension (3 positions) of the ring nut and the top of fuel tank to check the tightening condition of the ring nut.CAUTION:
- If the measured value exceeds the standard, retighten the ring nut to correct erroneous tightening of the ring nut.
- If the ring nut and ring nut plate are deformed, cracked or damaged, replace them with new parts.
Dimension of ring nut and top of fuel tank:
Standard
23.8 ±2.5 mm (0.937±0.098 in)
(A) Caliper with depth gauge (B) Ring nut (C) Fuel tank (D) Dimension of ring nut and top of fuel tank (E) Measuring point (F) Front side of vehicle - Connect the quick connector to the fuel sub level sensor. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE F) .
- Set the gasket and install the grommets.CAUTION:
- If the gasket is damaged, replace it with a new part.
- Make sure that the gasket is installed in the correct orientation.
- Make sure that the grommets are fully inserted.
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.