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Fuel Tank: Removal

WARNING: Place "NO OPEN FLAMES" signs near the working area.
CAUTION:
  • Be careful not to spill fuel.
  • Catch the fuel from the tubes using a container or cloth.
  1. Release the fuel pressure. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL>PROCEDURE>RELEASING OF FUEL PRESSURE .
  2. Drain fuel. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL>PROCEDURE>DRAINING FUEL (WITH SUBARU SELECT MONITOR) .
  3. Disconnect the ground terminal from battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
  4. Remove the cushion assembly rear seat LH and the cushion assembly rear seat RH. Ref. to SEATS>REAR SEAT>REMOVAL .
  5. Remove the service hole cover LH of fuel pump.
    1. Push in the grommet to remove the grommet from the service hole cover LH.
      G16523395Courtesy of SUBARU OF AMERICA, INC.
    2. Carefully remove the butyl tape and remove the service hole cover LH.
      CAUTION: To prevent deformation of the service hole cover, use special care not to apply excessive force to the service hole cover during the work.
      G16523396Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the butyl tape from the floor and the service hole cover LH.
  6. Disconnect the connector from fuel pump.
    G16523397Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the service hole cover RH of fuel sub level sensor.
    1. Push in the grommet to remove the grommet from the service hole cover RH.
      G16523398Courtesy of SUBARU OF AMERICA, INC.
    2. Carefully remove the butyl tape and remove the service hole cover RH.
      CAUTION: To prevent deformation of the service hole cover, use special care not to apply excessive force to the service hole cover during the work.
      G16523399Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the butyl tape from the floor and the service hole cover RH.
  8. Disconnect the connector from the fuel sub level sensor.
    G16523400Courtesy of SUBARU OF AMERICA, INC.
  9. Lift up the vehicle.
  10. Remove the fuel tank protector. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL TANK PROTECTOR>REMOVAL .
  11. Remove the rear suspension assembly. Ref. to REAR SUSPENSION>SUB FRAME>REMOVAL .
  12. Disconnect the fuel filler hose (A), circulate tube (B) and vent tube (C).

    Circulate tube: 

    Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE D) .

    Vent tube: 

    Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE H) .

    G16523401Courtesy of SUBARU OF AMERICA, INC.
  13. Disconnect the fuel delivery tube (A) and fuel delivery tube (B) from the fuel pipe assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE E) .
    G16523402Courtesy of SUBARU OF AMERICA, INC.
  14. Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and remove the fuel tank from the vehicle.
    CAUTION:
    • A helper is required to perform this work.
    • Fuel may remain in the fuel tank. This will cause the left and right sides to be unbalanced. Be careful not to drop it.
    G16523403Courtesy of SUBARU OF AMERICA, INC.
  15. Disconnect the fuel delivery tube from the fuel pump and remove it from the clamp. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE D) .
G16523404Courtesy of SUBARU OF AMERICA, INC.
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