Subaru Car 1998-05

Fuel Pump

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Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of the fuel pump assembly

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. On the 2000-03 Legacy, Outback and turbocharged models, perform the following:
    1. Raise and safely support the vehicle.
    2.  
    3. Remove the front side fuel tank cover.
    4.  
    5. Drain the fuel tank into a suitable container.
    6.  
    7. Tighten the drain plug to 14-24 ft. lbs. (19-33 Nm).
    8.  
    9. Install the front side fuel tank cover Tighten the retainers to 9.4-16.6 ft. lbs. (13-23 Nm).
    10.  

  8.  
  9. Remove or disconnect the following:

    Rear seat bottom, to reach the fuel pump access cover, if not already done
     

  10.  
  11. On Legacy models, fold the seat back, then roll the floor mat back.

    Fuel pump cover mounting bolts and the cover
     
    Electrical harness from the pump assembly
     

  12.  


NOTE
Label the fuel lines before disconnecting them from the pump.



Fuel lines from the fuel pump
 
Fuel pump mounting nuts
 
Fuel pump assembly from the tank
 

To install:

  1. Install or connect the following:

    New gasket
     
    Fuel pump assembly into the fuel tank and secure with the mounting nuts. Tighten the nuts to 24-48 inch lbs. (3-6 Nm) on non turbo models and 3 ft. lbs. (4 Nm) on turbo models.
     
    Electrical harness to the fuel pump assembly
     
    Fuel lines to the pump assembly, then tighten the clamps and fittings
     
    Fuel pump service cover and cover mounting bolts
     
    Rear seat bottom
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  



Click image to see an enlarged view

Fig. Exploded view of the fuel pump assembly

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. On the 2000-02 Legacy, perform the following:
    1. Raise and safely support the vehicle.
    2.  
    3. Remove the front side fuel tank cover.
    4.  
    5. Drain the fuel tank into a suitable container.
    6.  
    7. Tighten the drain plug to 14-24 ft. lbs. (19-33 Nm).
    8.  
    9. Install the front side fuel tank cover Tighten the retainers to 9.4-16.6 ft. lbs. (13-23 Nm).
    10.  

  8.  
  9. Remove or disconnect the following:

    Rear seat bottom, to reach the fuel pump access cover, if not already done
     

  10.  
  11. On Legacy models, fold the seat back, then roll the floor mat back.
    NOTE
    Label the fuel lines before disconnecting them from the pump.



    Fuel pump cover mounting bolts and the cover
     
    Electrical harness from the pump assembly
     



    Fuel lines from the fuel pump
     
    8 fuel pump mounting nuts
     
    Fuel pump assembly from the tank
     

  12.  

To install:

  1. Install or connect the following:

    New gasket
     
    Fuel pump assembly into the fuel tank and secure with the mounting nuts. Tighten the nuts to 24-48 inch lbs. (3-6 Nm).
     
    Electrical harness to the fuel pump assembly
     
    Fuel lines to the pump assembly, then tighten the clamps and fittings
     
    Fuel pump service cover and cover mounting bolts
     
    Rear seat bottom
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  



Click image to see an enlarged view

Fig. Fuel pump and related components-1998-2004 vehicles

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. On the 2000-2003 Legacy, Outback and turbocharged vehicles, perform the following:
    1. Raise and safely support the vehicle.
    2.  
    3. Remove the front side fuel tank cover.
    4.  
    5. Drain the fuel tank into a suitable container.
    6.  
    7. Tighten the drain plug to 14-24 ft. lbs. (19-33 Nm).
    8.  
    9. Install the front side fuel tank cover Tighten the retainers to 9.4-16.6 ft. lbs. (13-23 Nm).
    10.  

  6.  
  7. Remove or disconnect the following:

    Rear seat bottom, to reach the fuel pump access cover, if not already done
     

  8.  
  9. On the Legacy models, fold the seat back, then roll the floor mat back.
    NOTE
    Label the fuel lines before disconnecting them from the pump.



    Fuel pump cover mounting bolts and the cover
     
    Electrical harness from the pump assembly
     



    Fuel lines from the fuel pump
     
    Fuel pump mounting nuts
     
    Fuel pump assembly from the tank
     

  10.  

To install:

  1. Install or connect the following:

    New gasket
     
    Fuel pump assembly into the fuel tank and secure with the mounting nuts. Tighten the nuts to 24-48 inch lbs. (3-6 Nm) on non turbocharged engine and 3 ft. lbs. (4 Nm) on turbocharged engine.
     
    Electrical harness to the fuel pump assembly
     
    Fuel lines to the pump assembly, then tighten the clamps and fittings
     
    Fuel pump service cover and cover mounting bolts
     
    Rear seat bottom
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel filler cap.
  6.  
  7. Raise and support the vehicle safely.
  8.  
  9. Drain the fuel from the fuel tank into a suitable container.
  10.  
  11. Remove the luggage floor mat.
  12.  
  13. Remove the fuel pump access cover retaining screws. Remove the access cover.
  14.  
  15. Disconnect the electrical connector from the fuel pump.
  16.  
  17. Disconnect and plug the fuel line hoses at the fuel pump. Remove the clip and disconnect the jet pump hose.
  18.  
  19. Remove the fuel pump assembly retaining nuts. Remove the fuel pump from the vehicle.
  20.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use a new gasket and retainer.
  4.  
  5. Tighten the fuel pump retaining nuts to 3.3 ft. lbs. in an alternating sequence pattern.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Start the engine and check for leaks, correct as required.
  10.  

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel filler cap.
  6.  
  7. Raise and support the vehicle safely.
  8.  
  9. Drain the fuel from the fuel tank into a suitable container.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the rear seat.
  14.  
  15. Remove the fuel pump access cover retaining screws. Remove the access cover.
  16.  
  17. Disconnect the electrical connector from the fuel pump.
  18.  
  19. Disconnect and plug the fuel line hoses at the fuel pump. Remove the clip and disconnect the jet pump hose.
  20.  
  21. Remove the fuel pump assembly retaining nuts. Remove the fuel pump from the vehicle.
  22.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use a new gasket and retainer.
    NOTE
    When installing, point the protrusion of the gasket toward the front of the vehicle. Insert the protrusion of the gasket into the upper plate (three locations). Align the protrusion of the fuel pump assembly to the cutout in the upper plate.

  4.  
  5. Tighten the fuel pump retaining nuts to 3.2 ft. lbs. in an alternating sequence pattern.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Start the engine and check for leaks, correct as required.
  10.  

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel filler cap.
  6.  
  7. Raise and support the vehicle safely.
  8.  
  9. On the DOHC engine, remove the front side fuel tank cover.
  10.  
  11. Drain the fuel from the fuel tank into a suitable container.
    NOTE
    Vehicles equipped with the DOHC engine are equipped with a fuel tank drain plug. After draining the fuel tank, use a new gasket and replace the plug. Tighten the plug bolt to 19.2 ft. lbs.

  12.  
  13. Lower the vehicle.
  14.  
  15. Remove the rear seat. Turn the floor mat up.
  16.  
  17. Remove the fuel pump access cover retaining screws. Remove the access cover.
  18.  
  19. Disconnect the electrical connector from the fuel pump.
  20.  
  21. Disconnect and plug the fuel line hoses at the fuel pump.
  22.  
  23. Remove the fuel pump assembly retaining nuts. Remove the fuel pump from the vehicle.
  24.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use a new gasket and retainer.
  4.  
  5. Tighten the fuel pump retaining nuts to 4.3 ft. lbs. in an alternating sequence pattern.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Start the engine and check for leaks, correct as required.
  10.  

In-Tank Fuel Pumps
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the rear seat back and bottom cushion.
  6.  
  7. Remove the fuel pump access hole cover plate.
  8.  
  9. Disconnect the electrical harness from the fuel pump.
  10.  
  11. Disconnect and cap the fuel lines from the assembly.
  12.  
  13. Remove the eight screws securing the fuel pump assembly into the fuel tank.
  14.  
  15. Remove the unit from the vehicle.
  16.  

To install:

  1. Connect the fuel lines to the pump, then install the fuel sender on the pump assembly.
  2.  
  3. Connect the electrical harness to the fuel pump.
  4.  
  5. Install the fuel pump assembly in the fuel tank and install the eight mounting screws.
  6.  
  7. Connect the fuel lines to the fuel sender.
  8.  
  9. Connect the electrical harness to the fuel sender.
  10.  
  11. Install the fuel sender access hole cover.
  12.  
  13. Install the rear seat bottom and back.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the vehicle and check for leaks.
  18.  

Without In-Tank Fuel Pump
  1. Release the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the mat from the trunk floor.
  6.  
  7. Remove the access hole lid and disconnect the wiring harness.
  8.  
  9. Loosen the nuts and remove the unit.
  10.  

To install:

  1. Install the unit and tighten the nuts to 16-28 inch lbs. (2-3 Nm) in a star pattern.
  2.  
  3. Connect the wiring harness and install the access hole lid.
  4.  
  5. Install the trunk floor mat.

    Click image to see an enlarged view

    Fig. Fuel pump assembly mounted under the vehicle-1.8L engine

  6.  

 
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