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Fuel System (Fa20): Precautions

  1. Precautions before work
    1. Before performing the work related to the fuel system, perform the fuel spill prevention procedure and disconnect the negative terminal from the battery. (Refer to FUEL SYSTEM (FA20)  )
    2. Be sure not to perform the work related to the fuel system near open flames. Also be sure not to smoke during the work.
    3. Keep rubber and leather parts away from gasoline.
  2. Fuel spill prevention procedure
    CAUTION:
    • Perform this procedure when the engine coolant temperature is 60°C {140°F} or less.
    • Always perform the fuel spill prevention procedure before removing the fuel system parts.
    • Since a small amount of residue pressure exists in the fuel line after the fuel spill prevention procedure, prevent the fuel from splashing when disconnecting the fuel line.
    1. Remove the relay block cover UPR.
    2. Remove the fuel pump fuse from the engine compartment relay block.
      Fig 1: Locating Fuel Pump Fuse On Engine Compartment Relay Block
      G10213377Courtesy of SUBARU OF AMERICA, INC.
    3. Start the engine.
    4. Turn the ignition to OFF after the engine stalls by itself.
    5. Crank the engine again and check that it does not start.
      NOTE: Since a diagnostic code may be detected, check/clear the diagnostic code after the work is completed. (Refer to CHECKING/CLEARING DTC )
    6. Remove the fuel tank cap to release the pressure in the fuel tank.
    7. Disconnect the battery ground terminal. (Refer to WORKING PRECAUTIONS AND NOTES )
    8. Install the fuel pump fuse.
    9. Install the relay block cover UPR.
  3. Fuel system (quick type A)
    1. When disconnecting the fuel tube connector (quick type A), adhere to the following precautions.
      1. Release the two claws in the retainer of fuel tube connector and push down the retainer as shown in the figure to disconnect the fuel tube connector from the pipe.
        Fig 2: Disconnecting Fuel Tube Connector (Quick Type A)
        G10213378Courtesy of SUBARU OF AMERICA, INC.
      2. If the fuel tube connector is seized on the pipe, hold the pipe and push/pull the fuel tube connector to release it, and then disconnect the fuel tube connector.
        CAUTION:
        • Before starting the work, remove the foreign matters such as dirt on the fuel tube connector.
        • Since the fuel tube connector seals the fuel tube connector and pipe with the O-ring, pay special attention to the damage and foreign matters on the connection.
        • Never use any tools.
        • After the fuel tube is disconnected, protect the connection with a vinyl bag.
        • If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it, and then pull out it.
        Fig 3: Identifying Pipe, Retainer, Nylon Tube, Fuel Tube Connector, O-Ring And Top Hat
        G10213379Courtesy of SUBARU OF AMERICA, INC.
    2. When connecting the fuel tube connector (quick type A), adhere to the following precautions.
      1. Align the axis of fuel tube connector and the axis of pipe, then push in the fuel tube connector and push up the retainer.
        Fig 4: Connecting Fuel Tube Connector
        G10213380Courtesy of SUBARU OF AMERICA, INC.
      2. After the fuel tube connector is connected, pull the fuel tube connector and pipe to ensure they are connected securely.
        Fig 5: Checking Fuel Tube Connector
        G10213381Courtesy of SUBARU OF AMERICA, INC.
  4. Fuel system (quick type B)
    1. When disconnecting the fuel tube connector (quick type B) using the SST, adhere to the following precautions.
      1. Before disconnecting the fuel tube connector, check the fuel tube connector and pipe for dirt or dust. If dirt or dust is found, clean them.
      2. Attach the SST to the pipe. Push in the SST to disconnect the fuel tube connector from the pipe.

        SST 42099AE000

        Fig 6: Disconnecting Fuel Tube Connector (Quick Type B)
        G10213382Courtesy of SUBARU OF AMERICA, INC.
        CAUTION:
        • Hold the holding portion of the connector to pull out it in axial direction.
        • If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it with the SST pushed in, and then pull out fuel tube connector.
        • When disconnecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part.
        • Catch the fuel from the tube using a container to prevent it from splashing.
      3. After disconnecting the fuel tube, check the seal surface of pipe for dirt or dust.
      4. Make sure that the top hat or O-ring does not fall off.
      5. Protect the disconnected fuel tube connector and pipe with vinyl bags.
        Fig 7: Securing Fuel Tube Connector Using Vinyl Bags
        G10213383Courtesy of SUBARU OF AMERICA, INC.
        CAUTION:
        • When reusing the retainer, do not remove the retainer from the connector.
        • Do not damage the fuel tube connector and pipe or allow foreign matter to enter the pipe.
    2. When disconnecting the fuel tube connector (quick type B) without the SST, adhere to the following precautions.
      1. Before disconnecting the fuel tube connector, check the fuel tube connector and pipe for dirt or dust. If dirt or dust is found, clean them.
      2. Push the retainer in the direction of the arrow, disconnect the fuel tube connector from pipe.
        Fig 8: Pushing Retainer
        G10213384Courtesy of SUBARU OF AMERICA, INC.
        CAUTION:
        • Hold the holding portion of the connector to pull out it in axial direction.
        • If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it with the retainer pushed in, and then pull out fuel tube connector.
        • When disconnecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part.
        • Catch the fuel from the tube using a container to prevent it from splashing.
      3. After disconnecting the fuel tube, check the seal surface of pipe for dirt or dust.
      4. Make sure that the top hat or O-ring does not fall off.
      5. Protect the disconnected fuel tube connector and pipe with vinyl bags.
        Fig 9: Securing Fuel Tube Connector Using Vinyl Bags
        G10213385Courtesy of SUBARU OF AMERICA, INC.
        CAUTION:
        • When reusing the retainer, do not remove the retainer from the pipe.
        • Do not damage the fuel tube connector and pipe or allow foreign matter to enter the pipe.
    3. When connecting the fuel tube connector (quick type B), adhere to the following precautions.
      1. Make sure there are no damage or dust on connections. If necessary, clean the seal surface of pipe.
      2. When reusing the retainer, make sure that neither damage nor deformation exist on the retainer. If it is faulty, replace it with a new retainer.
        Fig 10: Identifying Fuel Tube Connector Seal Surface And Retainer
        G10213386Courtesy of SUBARU OF AMERICA, INC.
      3. Align the axis of fuel tube connector and the axis of pipe, push in the fuel tube connector until a clicking sound is heard from the retainer.
        Fig 11: Pushing Fuel Tube Connector
        G10213387Courtesy of SUBARU OF AMERICA, INC.
        CAUTION:
        • Hold the holding portion of the connector to push in it in axial direction.
        • When connecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part.
      4. After the fuel tube connector is connected, make sure that the fuel tube connector and pipe are connected securely.
        Fig 12: Connecting Fuel Tube Connector
        G10213388Courtesy of SUBARU OF AMERICA, INC.
        CAUTION:
        • Make sure that the two retainer pawls are engaged in their mating positions in the quick connector.
        • Make sure that there are no fuel leakages from the fuel tube and its connection.
  5. Fuel system (quick type C)
    1. When disconnecting a fuel pressure line, a large amount of gasoline will spill out. Perform the following procedure:
      1. Discharge fuel system pressure.
      2. Put a container under the connection.
      3. Disconnect the fuel pump tube.
      4. Drain the fuel remaining inside the fuel pump tube into the container.
      5. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination.
    2. Observe these precautions when connecting the fuel tube connector.
      1. Attach SST to the fuel pipe.

        SST 42099AE000

      2. Insert SST in the fuel tube connector side, and remove the fuel tube from the fuel pipe.
        Fig 13: Inserting SST In Fuel Tube Connector
        G10213389Courtesy of SUBARU OF AMERICA, INC.
      3. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    3. Observe these precautions when connecting the fuel tube connector.
      1. Check for damage or foreign matter on the connected part of the fuel pipe.
      2. Align the fuel tube connector axis with the fuel pipe axis, and push the fuel tube connector in until the retainer makes a clicking sound.
        Fig 14: Pushing Fuel Tube Connector
        G10213390Courtesy of SUBARU OF AMERICA, INC.
      3. After connecting the fuel tube connector, pull the fuel tube connector and pipe, and then push them to check that they are connected firmly.
        NOTE: Be sure to always finish checking the fuel pipe connections by pushing.
        Fig 15: Pulling Fuel Tube Connector
        G10213391Courtesy of SUBARU OF AMERICA, INC.
  6. Fuel system (evaporation hose connection)
    1. Connect the evaporation hose as shown in the figure.
      Fig 16: Identifying Hose, Clip, Spool And Pipe
      G10213392Courtesy of SUBARU OF AMERICA, INC.
      CAUTION: If there is no spool or stopper, connect the hose by inserting it into the pipe by 15 to 20 mm {0.591 to 0.787 in}.
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