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Home >> Subaru >> 2004 >> Baja Turbo, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection (Fuel Systems) (H4DOTC) >> Fuel Pump >> Removal

Fuel Pump: Removal

WARNING:
  • Place "NO FIRE" signs near the working area. 
  • Be careful not to spill fuel on the floor. 
  • During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill. 
NOTE: Fuel pump assembly consists of fuel pump and fuel level sensor.
  1. Release fuel pressure. Refer to FUEL .
  2. Open fuel filler flap lid and remove fuel filler cap.
  3. Disconnect battery ground cable.
    Fig 1: Disconnecting Battery Ground Cable
    G00928994Courtesy of SUBARU OF AMERICA, INC.
  4. Lift-up the vehicle.
  5. Remove front side fuel tank cover.
    Fig 2: Removing Front Side Fuel Tank Cover (1 Of 2)
    G00928995Courtesy of SUBARU OF AMERICA, INC.
    Fig 3: Removing Front Side Fuel Tank Cover (2 Of 2)
    G00928996Courtesy of SUBARU OF AMERICA, INC.
  6. Drain fuel from fuel tank. Set a container under the vehicle and remove drain plug from fuel tank.
    Fig 4: Removing Drain Plug From Fuel Tank
    G00928997Courtesy of SUBARU OF AMERICA, INC.
  7. Tighten fuel drain plug and install front right side fuel tank cover.
    NOTE: Replace gasket with new one.

    Tightening torque: 

    26 N.m (2.65 kgf-m, 19.2 ft-lb) 

    Fig 5: Tightening Fuel Drain Plug
    G00928998Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    18 N.m (1.8 kgf-m, 13.0 ft-lb) 

    Fig 6: Tightening Front Side Fuel Tank Cover (1 Of 2)
    G00928999Courtesy of SUBARU OF AMERICA, INC.
    Fig 7: Tightening Front Side Fuel Tank Cover (2 Of 2)
    G00929000Courtesy of SUBARU OF AMERICA, INC.
  8. Raise rear seat and turn floor mat up.
  9. Remove access hole lid.
    Fig 8: Removing Access Hole Lid
    G00929001Courtesy of SUBARU OF AMERICA, INC.
  10. Disconnect connector from fuel pump.
    Fig 9: Disconnecting Connector From Fuel Pump
    G00929002Courtesy of SUBARU OF AMERICA, INC.
  11. Move clips and then disconnect jet pump hose (C).
  12. Disconnect quick connector and then disconnect fuel delivery hose (A) and return hose (B). Refer to Fuel Delivery, Return and Evaporation Lines .
    Fig 10: Disconnecting Fuel Delivery Hose & Return Hose
    G00929003Courtesy of SUBARU OF AMERICA, INC.
  13. Remove nuts which install fuel pump assembly onto fuel tank.
    Fig 11: Removing Nuts
    G00929004Courtesy of SUBARU OF AMERICA, INC.
  14. Take off fuel pump assembly from fuel tank.