Fuel Filler Pipe: Removal

WARNING:

Place "NO FIRE" signs near the working area.
Be careful not to spill fuel on the floor.

Set the vehicle on the lift.
Disconnect battery ground cable.

Fig 1: Disconnecting Battery Ground Cable
Courtesy of SUBARU OF AMERICA, INC.
Open fuel filler flap lid and remove filler cap.
Remove screws holding packing in place.

Fig 2: Removing Screws Holding Packing In Place
Courtesy of SUBARU OF AMERICA, INC.
Lift-up the vehicle.
Remove rear wheel nuts.
Remove rear wheel.

Fig 3: Removing Rear Wheel
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Remove front right side fuel tank cover.

Fig 4: Removing Front Right Side Fuel Tank Cover
Courtesy of SUBARU OF AMERICA, INC.
Drain fuel from fuel tank. Set a container under the vehicle and remove drain plug from fuel tank.

Fig 5: Draining Fuel From Fuel Tank
Courtesy of SUBARU OF AMERICA, INC.
Tighten fuel drain plug and then install front right side tank cover.
NOTE: Replace gasket with new one.

Tightening torque:

26 N.m (2.65 kgf-m, 19.2 ft-lb)

Fig 6: Tightening Fuel Drain Plug
Courtesy of SUBARU OF AMERICA, INC.

Tightening torque:

18 N.m (1.8 kgf-m, 13.0 ft-lb)

Fig 7: Installing Front Right Side Tank Cover
Courtesy of SUBARU OF AMERICA, INC.
Remove rear exhaust pipe and muffler.
NOTE: To facilitate removal, apply a coat of SUBARU CRC to matching area of rubber cushions in advance.

SUBARU CRC (Part No. 004301003)
1. Separate rear exhaust pipe from center exhaust pipe.
  
  Fig 8: Removing Rear Exhaust Pipe From Center Exhaust Pipe
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove left and right rubber cushions.
  CAUTION: Be careful not to pull down muffler.
  
  Fig 9: Removing Left And Right Rubber Cushions
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove front rubber cushion and detach muffler assembly.
  
  Fig 10: Removing Front Rubber Cushion And Detach Muffler Assembly
  Courtesy of SUBARU OF AMERICA, INC.
Remove heat sealed cover.

Fig 11: Removing Heat Sealed Cover
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Place transmission jack under sub frame.

Fig 12: Placing Transmission Jack Under Sub Frame
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Remove bolt which holds rear shock absorber to rear suspension arm.

Fig 13: Removing Bolt Which Holds Rear Shock Absorber To Rear Suspension Arm
Courtesy of SUBARU OF AMERICA, INC.
Remove bolts which hold rear sub frame on body.

Fig 14: Removing Bolts Which Hold Rear Sub Frame On Body
Courtesy of SUBARU OF AMERICA, INC.
Lower the rear sub frame.
CAUTION: Be sure to lower sub frame slowly.

A = 150 mm (5.91 in)

Fig 15: Identifying Lower Rear Sub Frame
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Remove fuel filler pipe protector.

Fig 16: Removing Fuel Filler Pipe Protector
Courtesy of SUBARU OF AMERICA, INC.
Disconnect air vent hose (A) and evaporation hose (P) from evaporation pipe assembly.
Disconnect evaporation hose (H) from pressure control solenoid valve.

Fig 17: Disconnecting Evaporation Hose From Pressure Control Solenoid Valve
Courtesy of SUBARU OF AMERICA, INC.
Remove bolt which holds evaporation pipe assembly on body.

Fig 18: Removing Bolt Which Holds Evaporation Pipe Assembly On Body
Courtesy of SUBARU OF AMERICA, INC.
Disconnect fuel filler hose.
Remove bolt which holds fuel pressure sensor on fuel filler pipe and remove bolt which holds fuel filler pipe on body.

Fig 19: Removing Bolt Which Holds Fuel Pressure Sensor On Fuel Filler Pipe
Courtesy of SUBARU OF AMERICA, INC.
Disconnect canister hose from evaporation pipe assembly.

Fig 20: Disconnecting Canister Hose From Evaporation Pipe Assembly
Courtesy of SUBARU OF AMERICA, INC.
Disconnect evaporation hose (O) from fuel filler pipe.

Fig 21: Disconnecting Evaporation Hose From Fuel Filler Pipe
Courtesy of SUBARU OF AMERICA, INC.
Remove bolt which holds fuel filler pipe to body.

Fig 22: Removing Bolt Which Holds Fuel Filler Pipe To Body
Courtesy of SUBARU OF AMERICA, INC.
Remove fuel filler pipe from under side of the vehicle.