FPC Hardwire Kit Installation Guide - Stud Kit (All Models)

Table of Contents

1 Welcome!
2 Warning
3 Metal Hanger Fuel Pump Installation
4 Metal Hanger Step 1: Drill holes into the hanger for the stud kit
5 Metal Hanger Step 2: Install the Stud Kit Through the Hanger
6 Metal Hanger Step 3: Hooking Up Wiring to Stud Kit
7 Plastic Fuel Pump Hanger Installation
8 Plastic Hanger Step 1: Drill holes into the hanger for the stud kit.
9 Plastic Hanger Step 3: Hooking Up Wiring to Stud Kit
10 Related Install Videos

Welcome!

Thank you for purchasing the iWire Plug and Play Fuel Pump Hardwire Kit! These instructions are designed to make the installation process as easy as possible. Please read and follow them carefully.

We suggest reading the entire guide before beginning the installation of this product.

Warning

This kit is designed to modify your Subaru's electrical and fuel systems. Working around electricity and fuel vapors can be dangerous and even deadly if proper care is not taken. While iWire takes pride in making our products as simple as possible to use, we still recommend that a professional, qualified technician perform the installation. Any modification to a vehicle that exceeds the original manufacturer specifications (which includes OEM fuel tank connections) carries an inherent risk of mechanical failure that could result in damage to life or property. iWire is not responsible for any damages that may occur. By purchasing this product, you agree to these terms of sale.

Metal Hanger Fuel Pump Installation

USDM Models
2002-2007 WRX
2004-2007 STi
2004-2008 Forester Turbo
2004-2006 Baja Turbo

Click here for plastic hanger install tips

For metal fuel pump hangers, the thin black wire on the in-tank jumper harness will be trimmed as close to the terminal as you can. Leave this trimmed wire open and follow the rest of the installation instructions below.

Metal Hanger Step 1: Drill holes into the hanger for the stud kit

Drill a small pilot hole. Then, use a 15/64th drill bit to make the holes for the stud kit. We recommend measuring 1/2 inch or so from the OEM connector. Just keep the holes/stud kit away from the factory connector. Make sure the holes stay inside the line where the tank edge is.

Do not use any other size than a 15/64th drill bit.

Metal Hanger Step 2: Install the Stud Kit Through the Hanger

It is VERY IMPORTANT that these pieces be installed in this order. You can damage the wiring kit and your car if this is not done properly. This is to seal the fuel tank but also ensure that the metal of the studs do no touch the metal of the hanger.

Your kit will likely have black insulators with a built-in washer, so there will only be 1 additional washer per stud (2 washers total included in the kit). The process is the same as what is shown in our installation video. We recommend putting the black insulator/washer combination sleeve on the bottom side of the hanger to help ensure the hanger is sealed well. The separate washer will go on the top side of the hanger.

First, install the clear plastic insulators into the holes we’ve drilled into the hanger. We’ve included an extra set just in case a mistake is made.

Next, insert the metal stud into the insulator. You want to ensure the washer is between the metal stud and the insulator.

Once inserted into the insulator in the hanger, place the second washer on the back side so that the two washers sandwich the insulator into place.

Next, you’ll put the locking nut on the underside of the hanger (the side that goes into the gas tank) and tighten it into place with a 10 mm socket. This is done to ensure the insulator is compressed properly.

Once the locking nut has been fully tightened, go ahead and untighten it to remove the locking nut. Make sure to leave the washer in place. This may seem redundant, but trust us, it’s worth it.

Metal Hanger Step 3: Hooking Up Wiring to Stud Kit

Unplug the original harness from the fuel pump and plug the 2-pin black connector from the iWire FPC Hardwire Kit into it.

Place the ring terminals from the iWire FPC Hardwire Kit on each stud on top of the washer. Color order doesn’t matter here. You’ll just make sure that blue and blue touch and white touches white on the same stud. Put the locking nut back onto the stud and tighten it, ensuring the ring terminal is in place.

Make sure to plug the OEM 6-pin connector back into the hanger once you install it to keep fuel level and fuel temperature working correctly.

Route the wires to stay within the underside of the fuel pump hanger. That way, the wiring does not get pinched when the hanger goes back into the tank.

Once the underside of the hanger is complete, flip over the assembly and install the two ring terminals from the main jumper of the iWire FPC Hardwire Kit.

Make sure that the blue wire is connected to the stud with the blue wire on it underneath, and make sure white matches up to white.

Use the provided black acorn nut to secure the top ring terminal into place. The acorn nuts are insulated and nonconductive, which is VERY IMPORTANT to ensure this kit works properly. Be careful not to overtighten these.

Finally, plug the black 2-pin connector into the matching receptacle on the main harness.

Plastic Fuel Pump Hanger Installation

WARNING – DOUBLE CHECK CLEARANCE BOTH ABOVE (BRACKET/BRACING) AND BELOW (PUMP/HANGER TYPE/ETC) THE HANGER BEFORE DRILLING. THIS PLACEMENT WAS FOR A STANDARD HANGER AND SHOULD WORK FOR MOST APPLICATIONS. THE VISCONTI HANGER SITS PRETTY CLOSE TO TOP OF THE HANGER AND MAY REQUIRE MOVING THE STUDS TO A DIFFERENT LOCATION TO MAKE SURE IT DOES NOT TOUCH THE HANGER. IF THE STUDS TOUCH THE VISCONTI HANGER IT COULD CAUSE DAMAGE TO THE PUMP AND HARNESS

Plastic Hanger Step 1: Drill holes into the hanger for the stud kit.

Drill a small pilot hole. Then, use a 15/64^th drill bit to make the holes for the stud kit. We recommend drilling the hole between the plastic cross-hatch bracing on the underside.

Do not use any other size than a 15/64th drill bit.

Plastic Hanger Step 2: Install the Stud Kit Through the Hanger

It is VERY IMPORTANT that these pieces be installed in this order. You can damage the wiring kit and your car if this is not done properly. This is to seal the fuel tank but also ensure that the metal of the studs do no touch the hanger.

Your kit will likely have black insulators with a built-in washer, so there will only be 1 additional washer per stud (2 washers total included in the kit). The process is the same as what is shown in our installation video. We recommend putting the black insulator/washer combination sleeve on the bottom side of the hanger to help ensure the hanger is sealed well. The separate washer will go on the top side of the hanger.

Plastic Hanger Step 3: Hooking Up Wiring to Stud Kit

This step will be exactly the same as the metal hanger installation instructions above, except for one difference. When putting the ring terminals on the underside of the hanger, you’ll want to loop the wires. This will give enough slack in the wiring for when the hanger is extended.

Plastic Hanger Step 4: Hooking Up Ground Wire

With each kit comes a small metal crimp and a piece of plastic shrink tube. You’ll use these pieces to connect the black wire from the iWire FPC Hardwire Kit to the Black ground wire on the fuel pump hanger.

First, cut the wire to length. You’ll want a little slack, so give yourself a little extra length than you think you need.

Strip about 6-7mm on each side of the loose wires going into the crimp. This wire will be 20 GA.

Insert the shrink tube into one of the wires. (Do this before crimping!) Then, slide one of the stripped wires into one end of the metal crimp. Crimp tightly using a ratchet tool.

Repeat this step with the second wire and put it into the empty slot of the metal crimp. Crimp tightly. We suggest doing a light pull test to ensure the connection is secure.

Slide the shrink tube over this metal crimp once complete, and shrink it into place using a heat gun.

Once the ground wire is complete, you’ll install the Blue and White wires onto the top side of the hanger following the instructions from Step 3 of the metal hanger install.