Fuel Pump Assembly (Fa20): Removal

CAUTION: If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain the fuel before starting the work to avoid the fuel to spill.

Fuel spill prevention procedure (Refer to FUEL SYSTEM (FA20) )
Draining of fuel (method with SSM3)
1. If the fuel gauge indicates that two thirds or more of the fuel is remaining, drain the fuel according to the following procedure.
  CAUTION: Be careful not to spill fuel.
  NOTE:
  - If the fuel pump cannot be driven, refer to the method for draining the fuel from the fuel tank to filler pipe hose.
  - Be careful not to let the battery run-out.
  1. Put alignment marks on the fuel hoses on the port injection side and on the direct injection side.
    
    Fig 1: Locating Fuel Hoses Alignment Marks
    Courtesy of SUBARU OF AMERICA, INC.
  2. Using the SST, disconnect the port injection side fuel hose and cylinder injection side fuel hose.
    SST 42099AE000
    CAUTION:
    Before starting the work, remove the foreign matters such as dirt on the fuel hose connection.
    
    Be careful not to spill fuel.
    
    Catch the fuel from fuel hoses using a container.
  3. Connect the SST to the fuel hose.
    SST 18471AA000
  4. Connect a gasoline proof hose to the SST and put the hose end into the container.
  5. Drive the fuel pump and drain the fuel using the SSM3.
    CAUTION: Be careful not to spill fuel.
    
    NOTE: Always be sure to use a steel container and ground the container as gasoline can easily become charged with static electricity.
Draining of fuel (method from fuel tank to filler pipe hose)
1. If the fuel gauge indicates that two thirds or more of the fuel is remaining, drain the fuel according to the following procedure.
  WARNING: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
  CAUTION:
  - Be careful not to spill fuel.
  - Fuel may remain in the fuel filler pipe. Drain the fuel from the fuel filler pipe through the fill opening using a gasoline proof pump and gasoline proof hose with a diameter of 10 mm {0.3937 in} or less before starting the work.
  1. Remove the exhaust pipe Assembly CTR. (Refer to INSTALLATION )
  2. Remove the exhaust tail pipe Assembly. (Refer to INSTALLATION )
  3. Loosen the hose clamp and disconnect the fuel tank to filler pipe hose.
    CAUTION:
    Before starting the work, remove the foreign matters such as dirt on the fuel tank to filler pipe hose connection.
    
    Be careful not to spill fuel.
    Fig 2: Locating Filler Pipe Hose Clamp
    Courtesy of SUBARU OF AMERICA, INC.
  4. Set a metal container under the vehicle and drain the fuel from the fuel tank to filler pipe hose opening using the gasoline proof hose with a diameter of 10 mm {0.3937 in} or less.
    CAUTION: Be careful not to spill fuel.
    
    NOTE: Always be sure to use a steel container and ground the container as gasoline can easily become charged with static electricity.
  5. Install the fuel tank to filler pipe hose with the hose clamp.
    Standard value: T=2.0N.m {20kgf.cm} {1.5ft.lbf}
Disconnection of the battery ground terminal (Refer to WORKING PRECAUTIONS AND NOTES )
Separate type rear seat cushion Assembly LH removal (Refer to DISASSEMBLY )
Rear floor service hole cover No. 2 removal
1. Push in the grommet to remove the rear floor service hole cover No. 2.
2. Remove the butyl tape and remove the rear floor service hole cover No. 2.
  
  Fig 3: Locating Rear Floor Service Hole Cover
  Courtesy of SUBARU OF AMERICA, INC.
3. Disconnect the fuel pump connector.
  
  Fig 4: Disconnecting Fuel Pump Connector
  Courtesy of SUBARU OF AMERICA, INC.
Fuel pump Assembly removal
1. Disconnect the fuel delivery tube. (Refer to FUEL SYSTEM (FA20) )
  CAUTION: Be careful not to spill fuel.
  
  Fig 5: Locating Fuel Delivery Tube
  Courtesy of SUBARU OF AMERICA, INC.
  1. Remove the fuel delivery pipe from the fuel tank.
    
    Fig 6: Removing Fuel Delivery Pipe
    Courtesy of SUBARU OF AMERICA, INC.
2. Ring nut removal
  1. Use the SST to loosen the ring nut.
    SST 42099CA000
    CAUTION:
    Do not use any tools other than the SST.
    
    Be careful not to damage the tube with the SST.
    
    Before setting the SST, move the tube to a position outside the SST.
    NOTE: Insert the cutout portion of SST into the rib of ring nut to fix the SST securely.
3. Remove the ring nut and ring nut plate while holding the fuel pump Assembly by hand.
  
  Fig 7: Removing Ring Nut
  Courtesy of SUBARU OF AMERICA, INC.
4. Disconnect the fuel sub delivery tube and remove the fuel pump Assembly from the fuel tank.
  CAUTION:
  - When disconnecting the fuel sub delivery tube, do not pull the tube strongly.
  - Do not bend the arm of fuel sender gauge Assembly.
  - Do not turn the fuel pump Assembly in the fuel tank to prevent the arm of fuel sender gauge Assembly from bending.
  - Be careful not to spill the fuel remaining in the fuel pump Assembly outside the fuel tank or in the vehicle.
5. Remove the gasket from the fuel tank.