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Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Electric Fuel Pump

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REMOVAL & INSTALLATION



1.2L Engine

See Figures 1, 2 and 3

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Fig. Fig. 1: Fuel pump assembly-1.2L carbureted engine



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Fig. Fig. 2: Disconnect the arrowed fuel lines



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Fig. Fig. 3: Unfasten the indicated nuts to remove the fuel pump

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the three fuel pump/filter bracket bolts.
  4.  
  5. Place a drip pan beneath the fuel pump to catch any spilled fuel.
  6.  
  7. Pinch off the fuel lines from the fuel pump.
  8.  
  9. Disconnect the fuel pump electrical harness.
  10.  
  11. Remove the fuel pump-to-bracket bolts and remove the fuel pump.
  12.  

To install:
  1. Position the fuel pump on the bracket and install the mounting bolts.
  2.  
  3. Connect the electrical harness to the fuel pump.
  4.  
  5. Connect the fuel lines to the fuel pump.
  6.  
  7. Position the fuel pump/filter bracket and install the three mounting bolts.
  8.  
  9. Connect the negative battery cable.
  10.  

1.6L and 1.8L Engines

See Figure 4

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Fig. Fig. 4: Fuel pump assembly-1.6L and 1.8L carbureted engines

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Place a drip pan beneath the inlet side fuel connection.
  6.  
  7. Pinch off the inlet side of the fuel filter to minimize fuel loss.
  8.  
  9. Disconnect the electrical harness from the fuel pump.
  10.  
  11. Remove the three screws securing the fuel bracket to the vehicle and pull the bracket and pump down as a unit.
  12.  
  13. Remove the three nuts securing the fuel pump to the bracket.
  14.  
  15. Disconnect the inlet and outlet hoses from the fuel pump.
  16.  
  17. Remove the pump from the vehicle.
  18.  
  19. Remove the fuel pump-to-bracket bolts and remove the fuel pump.
  20.  

To install:
  1. Install the mounting cushions to the fuel pump.
  2.  
  3. Position the fuel pump on the mounting bracket and install the three mounting nuts and washers.
  4.  
  5. Connect the inlet and outlet lines to the fuel pump.
  6.  
  7. Position the pump and bracket assembly to the frame and install the three mounting bolts.
  8.  
  9. Install the clips securing the fuel pipes to the fuel line assembly.
  10.  
  11. Connect the electrical harness to the fuel pump.
  12.  
  13. Unclamp the fuel inlet line.
  14.  
  15. Lower the vehicle.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Pressurize the fuel system and verify that there are no leaks.
  20.  

PRESSURE TESTING



  1. Raise and support the vehicle safely on jackstands.
  2.  
  3. Disconnect the fuel line at the outlet side of the fuel pump, then connect a fuel pressure gauge to the fuel pump.
  4.  
  5. Turn the ignition switch ON and observe the fuel pressure; it should be 2.6-3.3 psi (5.2-6.6 in Hg). If the fuel pump does not meet this specification, replace the pump.
  6.  
  7. After testing, disconnect the pressure gauge and reconnect the fuel line.
  8.  
  9. Lower the vehicle.
  10.  

 
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