Draining Fuel: Removal & Installation Subaru Outback BH

REMOVAL

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

1. Set the vehicle on the lift.
2. Disconnect battery ground cable. (Scheme 82): Disconnecting Battery Ground Cable
3. Open fuel filler flap lid and remove filler cap. (Scheme 83): Removing Filler Cap
4. Remove screws holding packing in place. (Scheme 84): Removing Packing Screws
5. Lift-up the vehicle.
6. Remove rear wheel nuts.
7. Remove rear wheel. (Scheme 85): Removing Rear Wheel
8. Remove front right side fuel tank cover. (Scheme 86): Removing Front Right Side Fuel Tank Cover
9. Drain fuel from fuel tank. Set a container under the vehicle and remove drain plug from fuel tank. (Scheme 87): Draining Fuel From Fuel Tank
10. Tighten fuel drain plug and then install front right side tank cover. Tightening torque: 26 N.m (2.65 kgf-m, 19.2 ft-lb) (Scheme 88): Tightening Fuel Drain Plug Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) (Scheme 89): Installing Front Right Side Tank Cover
11. 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) Separate rear exhaust pipe from center exhaust pipe. (Scheme 90): Separating Rear Exhaust Pipe From Center Exhaust Pipe Remove left and right rubber cushions. CAUTION: Be careful not to pull down muffler. (Scheme 91): Removing Left & Right Rubber Cushions Remove front rubber cushion and detach muffler assembly. (Scheme 92): Detaching Muffler Assembly
12. Remove heat sealed cover. (Scheme 93): Removing Heat Sealed Cover
13. Place transmission jack under sub frame. (Scheme 94): Placing Transmission Jack Under Sub Frame
14. Remove bolt which holds rear shock absorber to rear suspension arm. (Scheme 95): Removing Rear Shock Absorber Bolt
15. Remove bolts which hold rear sub frame on body. (Scheme 96): Removing Rear Sub Frame Bolts
16. Lower the rear sub frame. CAUTION: Be sure to lower sub frame slowly. A = 150 mm (5.91 in) (Scheme 97): Lowering Rear Sub Frame
17. Remove fuel filler pipe protector. (Scheme 98): Removing Fuel Filler Pipe Protector
18. Disconnect air vent hose (A) and evaporation hose (H) from evaporation pipe assembly.
19. Disconnect evaporation hose (I) from pressure control solenoid valve. (Scheme 99): Disconnecting Air Vent Hose & Evaporation Hose From Evaporation Pipe Assembly
20. Remove bolt which holds evaporation pipe assembly on body. (Scheme 100): Removing Bolt Holding Evaporation Pipe
21. Disconnect fuel filler hose.
22. Remove bolt which holds fuel pressure sensor on fuel filler pipe and remove bolt which holds fuel filler pipe on body. (Scheme 101): Removing Fuel Pressure Sensor & Fuel Filler Bolts
23. Disconnect canister hose from evaporation pipe assembly. (Scheme 102): Disconnecting Canister Hose
24. Disconnect evaporation hose (O) from fuel filler pipe. (Scheme 103): Disconnecting Evaporation Hose From Fuel Filler Pipe
25. Remove bolt which holds fuel filler pipe to body. (Scheme 104): Removing Bolt Holding Fuel Filler Pipe
26. Remove fuel filler pipe to under side of the vehicle.

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

1. Hold fuel filler flap open.
2. Set fuel saucer (A) with rubber packing (C) and insert fuel filler pipe into hole from the inner side of apron. (Scheme 105): Setting Fuel Saucer With Rubber Packing
3. Align holes in fuel filler pipe neck and set cup (B), and tighten screws. NOTE: If edges of rubber packing are folded toward the inside, straighten it with a screwdriver. (Scheme 106): Aligning Holes In Fuel Filler Pipe Neck & Setting Cup
4. Tighten bolt which holds fuel filler pipe on body. Tightening torque: 7.5 N.m (0.75 kgf-m, 5.4 ft-lb) (Scheme 107): Tightening Bolt Holding Fuel Filler Pipe
5. Insert evaporation hose (O) approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe and hold clip. (Scheme 108): Inserting Evaporation Hose Into Lower End Of Evaporation Pipe & Hold Clip L = 27.5+/-2.5 mm (1.083+/-0.098 in) (Scheme 109): Identifying Evaporator Hose Position
6. Insert canister hoses approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe assembly and tighten clamp. (Scheme 110): Inserting Canister Hoses L = 27.5+/-2.5 mm (1.083+/-0.098 in) (Scheme 111): Inserting Vent & Evaporator Hoses
7. Tighten bolt which holds evaporation pipe assembly on body. Tightening torque: 7.5 N.m (0.75kgf-m, 5.4 ft-lb) (Scheme 112): Tightening Bolt Holding Evaporation Pipe Assembly On Body
8. Insert air vent hose (A), evaporation hose (H) approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe assembly and hold clip.
9. Insert evaporation hose (I) to pressure control solenoid valve and hold clip. (Scheme 113): Inserting Air Vent Hose, Evaporation Hose Into Lower End Of Evaporation Pipe Assembly & Holding Clip L = 27.5+/-2.5 mm (1.083+/-0.098 in) (Scheme 114): Identifying Hose Positions
10. Tighten bolt which holds fuel filler pipe on body and tighten bolt which holds fuel pressure sensor on fuel filler pipe. Tightening torque: 7.5 N.m (0.75 kgf-m, 5.4 ft-lb)
11. Insert fuel filler hose approximately 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe and tighten clamp. (Scheme 115): Inserting Fuel Filler Hose Over Lower End Of Fuel Filler Pipe
12. Jack-up the rear sub frame and tighten bolts which hold rear sub frame on body. Tightening torque: T1: 66 N-m (6.7 kgf-m, 48.5 ft-lb) T2: 172 N.m (17.5 kgf-m, 127 ft-lb) (Scheme 116): Tightening Bolts T1 & T2
13. Tighten bolt which holds rear shock absorber to rear suspension arm. See «INSTALLATION»(ref-167883-S15576379152004120600000), Rear Shock Absorber. Tightening torque: 157 N.m (16 kgf-m, 116 ft-lb) (Scheme 117): Tightening Rear Shock Absorber Bolt
14. Install heat shield cover. (Scheme 118): Installing Heat Shield Cover
15. Install rear exhaust pipe and muffler. NOTE: To facilitate the procedure, apply a coat of SUBARU CRC to matching area of rubber cushions in advance. SUBARU CRC (Part No. 004301003) Install left and right rubber cushions. (Scheme 119): Installing Left & Right Rubber Cushions Install front rubber cushion and attach muffler assembly. (Scheme 120): Installing Front Rubber Cushion & Attaching Muffler Install rear exhaust pipe to center exhaust pipe. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) (Scheme 121): Installing Rear Exhaust Pipe To Center Exhaust Pipe
16. Install fuel filler pipe protector. (Scheme 122): Installing Fuel Filler Pipe Protector
17. Install rear right wheel. (Scheme 123): Installing Rear Right Wheel
18. Lower the vehicle.
19. Tighten wheel nuts.
20. Connect battery ground terminal. (Scheme 124): Connecting Battery Ground Terminal
21. Remove fuel filler pipe to under side of the vehicle.

Scheme 125

Scheme 126

Scheme 127

1. Disconnect evaporation hose (M) and (N) from evaporation pipe assembly. (Scheme 125): Disconnecting Evaporation Hose & From Evaporation Pipe Assembly
2. Remove shut valve from fuel filler pipe. (Scheme 126): Removing Shut Valve From Fuel Filler Pipe
3. Remove nut which holds evaporation pipe assembly on fuel filler pipe. (Scheme 127): Removing Nut Holding Evaporation Pipe Assembly

Note. Fuel pump assembly consists of fuel pump and fuel level sensor.

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

1. Release fuel pressure. See «RELEASING OF FUEL PRESSURE»(ref-178257-S00004179312005061300000), OPERATION, Fuel.
2. Open fuel filler flap lid and remove fuel filler cap. (Scheme 128): Removing Fuel Filler Cap
3. Disconnect battery ground cable. (Scheme 129): Disconnecting Battery Ground Cable
4. Lift-up the vehicle.
5. Remove front side fuel tank cover. (Scheme 130): Removing Front Side Fuel Tank Cover
6. Drain fuel from fuel tank. Set a container under the vehicle and remove drain plug from fuel tank. (Scheme 131): Draining Fuel From Fuel Tank
7. Tighten fuel drain plug and install front right side fuel tank cover. Tightening torque: 26 N.m (2.65 kgf-m, 19.2 ft-lb) (Scheme 132): Tightening Fuel Drain Plug Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) (Scheme 133): Installing Front Right Side Fuel Tank Cover
8. Raise rear seat and turn floor mat up.
9. Remove access hole lid. (Scheme 134): Removing Access Hole Lid
10. Disconnect connector from fuel pump. (Scheme 135): Disconnecting Connector From Fuel Pump
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). See «REMOVAL»(ref-178257-S25782686432005061400000), Fuel Delivery, Return and Evaporation Lines. (Scheme 136): Disconnecting Fuel Delivery Hose & Return Hose
13. Remove nuts which install fuel pump assembly onto fuel tank. (Scheme 137): Removing Nuts Installing Fuel Pump Assembly
14. Take off fuel pump assembly from fuel tank.

INSTALLATION

Install in the reverse order of removal. Do the following

Scheme 138

1. Always use new gaskets.
2. Ensure sealing portion is free from fuel or foreign particles before installation.
3. Tighten nuts in alphabetical sequence shown in figure to specified torque. Tightening torque: 5.9 N.m (0.6 kgf-m, 4.3 ft-lb) (Scheme 138): Tightening Nuts In Alphabetical Sequence

Scheme 139

Scheme 140

1. Remove fuel pump and pump holder. NOTE: When disassembling pump holder, be careful as it is installed with two pawls. (Scheme 139): Removing Fuel Pump & Pump Holder
2. Disconnect connector from fuel pump. (Scheme 140): Disconnecting Connector From Fuel Pump

Note. Fuel level sensor is built in fuel pump assembly.

Scheme 141

Scheme 142

1. Remove fuel pump assembly. See «REMOVAL»(ref-178257-S37382967922005061300000), Fuel Pump.
2. Disconnect connector from fuel pump bracket. (Scheme 141): Disconnecting Connector From Fuel Pump Bracket
3. Pushing the pawls with a screwdriver, remove fuel meter unit by pulling it downwards. NOTE: Replace fuel filter pawls with new ones as they might break when removed. (Scheme 142): Removing Fuel Meter

Install in the reverse order of removal.

Connecting Ground Cable. Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

1. Disconnect battery ground cable. (Scheme 144): Disconnecting Battery Ground Cable
2. Lift-up the vehicle.
3. Remove front side fuel tank cover. (Scheme 145): Removing Front Side Fuel Tank Cover
4. Drain fuel from fuel tank. Set a container under the vehicle and remove drain plug from fuel tank. (Scheme 146): Draining Fuel From Fuel Tank
5. Tighten fuel drain plug and install front right side fuel tank cover. Tightening torque: 26 N.m (2.65 kgf-m, 19.2 ft-lb) (Scheme 147): Tightening Fuel Drain Plug Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) (Scheme 148): Installing Front Right Side Fuel Tank Cover
6. Raise rear seat and turn floor mat up. (Wagon model)
7. Remove rear seat. (Sedan model)
8. Remove service hole cover. (Scheme 149): Removing Service Hole Cover
9. Disconnect connector from fuel sublevel sensor. (Scheme 150): Disconnecting Connector From Fuel Sublevel Sensor
10. Disconnect fuel jet pump hose. (Scheme 151): Disconnecting Fuel Jet Pump Hose
11. Remove bolts which install fuel sublevel sensor on fuel tank. (Scheme 152): Removing Sublevel Sensor
12. Remove fuel sub level sensor.

Install in the reverse order of removal.

1. Tightening torque: 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

Identifying Fuel Pump/Sensor Fasteners. Scheme 153

Scheme 154

1. Release fuel pressure. See «RELEASING OF FUEL PRESSURE»(ref-178257-S00004179312005061300000), OPERATION, Fuel.
2. Disconnect fuel delivery hoses from fuel filter. (Scheme 154): Disconnecting Fuel Delivery Hoses From Fuel Filter
3. Remove filter from holder.

Scheme 155

1. Install in the reverse order of removal.
2. Tighten hose clamp screws. Tightening torque: 1.0 N.m (0.1 kgf-m, 0.7 ft-lb) (Scheme 155): Tightening Hose Clamp Screws

Install in the reverse order of removal.

1. Tightening torque: 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

Installing Fuel Cut Valve Bolts. Scheme 156

Scheme 157

Scheme 158

Scheme 159

1. Set vehicle on the lift.
2. Release fuel pressure. See «RELEASING OF FUEL PRESSURE»(ref-178257-S00004179312005061300000), OPERATION, Fuel.
3. Open fuel filler flap lid and remove fuel filler cap.
4. Remove fuel tank. See «REMOVAL»(ref-178257-S07231099952005061300000), Fuel Tank.
5. Remove fuel filler pipe. See «REMOVAL»(ref-178257-S27469988972005061300000), Fuel Filler Pipe.
6. Remove floor mat. See «REMOVAL»(ref-175480-S32586428062005042100000), Floor Mat.
7. Remove fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses. (Scheme 157): Removing Fuel Delivery Pipes & Hoses
8. In engine compartment, detach fuel deliver hoses, return hoses and evaporation hose. (Scheme 158): Identifying Fuel Hoses
9. Separate quick connector on fuel delivery, return line and evaporation line. Clean pipe and connector, if they are covered with dust. Hold connector (A) and push retainer (B) down. Pull out connector (A) from retainer (B). CAUTION: Replace retainer with new ones. (Scheme 159): Separating Quick Connectors On Fuel Delivery

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

1. Connect quick connector on fuel delivery and return line. CAUTION: Always use a new retainer. Make sure that the connected portion is not damaged or has dust. If necessary, clean seal surface of pipe. (Scheme 160): Connecting Quick Connector On Fuel Delivery & Return Line NOTE: At this time, clicking sound can be heard two times. (Scheme 161): Connecting Quick Connector On Fuel Delivery & Return Line CAUTION: Pull the connector to ensure it is connected securely. Ensure the two retainer pawls are engaged in their mating positions in the connector. Be sure to inspect hoses and their connections for any leakage of fuel. (Scheme 162): Identifying Connector, Retainer & Pipe
2. Connect fuel delivery hose to pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in). Type A: When fitting length is specified. Type B: When fitting length is not specified. l: 2.5+/-1.5 mm (0.098+/-0.059 in) L: 22.5+/-2.5 mm (0.886+/-0.098 in) (Scheme 163): Connecting Fuel Delivery Hose To Pipe
3. Connect evaporation hose to pipe by approx. 15 mm (0.59 in) from hose end. L = 17.5+/-2.5 mm (0.689+/-0.098 in) CAUTION: Be sure to inspect hoses and their connections for any leakage of fuel. (Scheme 164): Connecting Evaporation Hose To Pipe From Hose End