Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Electric Fuel Pump

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REMOVAL & INSTALLATION



1.2L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rear seat back and bottom cushion.
  4.  
  5. Remove the fuel sender access hole cover plate.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Disconnect the electrical harness from the fuel pump.
  10.  
  11. Disconnect and cap the fuel lines from the fuel sender assembly.
  12.  
  13. Remove the eight screws securing the fuel assembly into the fuel tank.
  14.  
  15. Remove the fuel sender assembly.
  16.  
  17. Remove the filter strainer from the fuel pump.
  18.  
  19. Disconnect the electrical harness from the fuel pump.
  20.  
  21. Disconnect the fuel lines from the pump.
  22.  
  23. Remove the pump from the sender assembly.
  24.  

To install:
  1. Connect the fuel lines to the pump, then install the pump on the sender assembly.
  2.  
  3. Connect the electrical harness to the fuel pump.
  4.  
  5. Install a new fuel strainer on the pump.
  6.  
  7. Install the fuel sender assembly in the fuel tank and install the eight mounting screws.
  8.  
  9. Connect the fuel lines to the fuel sender.
  10.  
  11. Connect the electrical harness to the fuel sender.
  12.  
  13. Install the fuel sender access hole cover.
  14.  
  15. Install the rear seat bottom and back.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the vehicle and check for leaks.
  20.  

1.8L Engine

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Fuel pump assembly-1.8L MPFI engines

  1. Release the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Keep the fuel pump harness disconnected after releasing the fuel system pressure.
  6.  
  7. Raise and support the vehicle safely on jackstands.
  8.  
  9. Clamp the middle portion of the hose connecting the pipe to the fuel pump to prevent fuel from flowing out of the tank.
  10.  
  11. Loosen the hose clamp and disconnect the hose.
  12.  
  13. Remove the three pump bracket mounting bolts and remove the pump together with the pump damper.
  14.  

To install:
  1. If the pump and damper have been removed from the bracket, reinstall and tighten the bolts securely.
  2.  
  3. Install the hose and tighten the clamp screw to 9-13 inch lbs. (1.0-1.5 Nm).
  4.  
  5. Install the pump bracket in position to the vehicle body and secure it with the bolts.
  6.  

Take care to position the rubber cushion properly.

  1. Connect the pump harness connector.
  2.  
  3. Connect the negative battery cable and test the fuel pump for proper operation.
  4.  
  5. Check for leaks.
  6.  

2.2L, 2.5L and 2.7L Engines

See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: Fuel pump assembly-2.2L, 2.5L and 2.7L engines


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the rear seat bottom to reach the fuel pump access cover.
  6.  
  7. On Legacy models, fold the seat back, then roll the floor mat back.
  8.  
  9. Remove the fuel pump cover mounting bolts, then remove the fuel pump cover.
  10.  
  11. Disconnect the electrical harness from the pump assembly.
  12.  
  13. Tag and disconnect the fuel lines from the fuel pump.
  14.  
  15. Remove the eight fuel pump mounting nuts.
  16.  
  17. Remove the fuel pump assembly from the tank.
  18.  

To install:
  1. Using a new gasket, install the fuel pump assembly into the fuel tank and install the fuel pump mounting nuts. Tighten the nuts to 20-33 inch lbs. (2-4 Nm) on Impreza models, 24-48 inch lbs. (3-6 Nm) for Legacy models.
  2.  
  3. Connect the electrical harness to the fuel pump assembly.
  4.  
  5. Connect the fuel lines to the pump assembly and tighten the clamps and fittings.
  6.  
  7. Install the fuel pump service cover and cover mounting bolts.
  8.  
  9. Install the rear seat bottom.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and check for leaks.
  14.  

3.3L Engine

See Figures 3 and 4

Click image to see an enlarged view

Fig. Fig. 3: Fuel pump assembly-3.3L engine



Click image to see an enlarged view

Fig. Fig. 4: Carefully remove the fuel pump assembly from the tank


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect and tag the four hoses from the fuel sender assembly.
  6.  
  7. Remove the fuel sender retaining cap using 42911PA000 or equivalent.
  8.  
  9. Take out the left side fuel meter assembly.
  10.  
  11. Take out the right side fuel meter assembly.
  12.  
  13. Remove the fuel pump assembly.
  14.  

To install:
  1. Install the fuel pump assembly.
  2.  
  3. Install the right side fuel meter assembly.
  4.  
  5. Install the left side fuel meter assembly.
  6.  
  7. Install the bracket covers.
  8.  
  9. Install the fuel sender retaining cap using 42911PA000, or an equivalent replacer.
  10.  
  11. Connect the four hoses to the sender assembly.
  12.  
  13. Connect the electrical harness to the sender assembly.
  14.  
  15. Install the fuel pump access cover.
  16.  
  17. Connect the negative battery cable.
  18.  

TESTING



See Figure 5

Click image to see an enlarged view

Fig. Fig. 5: Testing the fuel pressure with a gauge

  1. Turn the ignition ON and listen for the fuel pump to make a growling sound. Turn the ignition OFF .
  2.  
  3. Release the fuel system pressure. Disconnect the pump connector and crank the engine for 5 seconds or more. If the engine starts, allow it to run until it stops. Turn the ignition OFF and install the fuel pump connector.
  4.  
  5. Disconnect the fuel hose at the fuel pump.
  6.  
  7. Connect a gauge in-line using a T-fitting.
  8.  
  9. Start the engine and measure the fuel pressure. The pressure 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.
  10.  
  11. After testing, disconnect the pressure gauge and reconnect the fuel line.
  12.  

 
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