2002 Subaru Outback Base, 4D SedanFACTORY OEM SERVICE PROCEDURE

Fuel Sub Level Sensor: Removal

WARNING:
  • Place "NO FIRE" signs near the working area.
  • Be careful not to spill fuel on the floor.
  1. Disconnect battery ground cable.
    Fig 1: Disconnecting Battery Ground Cable
    G03584411Courtesy of SUBARU OF AMERICA, INC.
  2. Lift-up the vehicle.
  3. Remove front side fuel tank cover.
    Fig 2: Removing Front Side Fuel Tank Cover
    G03584412Courtesy of SUBARU OF AMERICA, INC.
  4. Drain fuel from fuel tank. Set a container under the vehicle and remove drain plug from fuel tank.
    Fig 3: Removing Drain Plug From Fuel Tank
    G03584413Courtesy of SUBARU OF AMERICA, INC.
  5. Tighten fuel drain plug and install front right side fuel tank cover.

    Tightening torque:Β 

    26 N.m (2.65 kgf-m, 19.2 ft-lb)Β 

    Fig 4: Tightening Fuel Drain Plug (1 Of 2)
    G03584414Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque:Β 

    18 N.m (1.8 kgf-m, 13.0 ft-lb)Β 

    Fig 5: Tightening Fuel Drain Plug (2 Of 2)
    G03584415Courtesy of SUBARU OF AMERICA, INC.
  6. Raise rear seat and turn floor mat up. (Wagon model)
  7. Remove rear seat. (Sedan model)
  8. Remove service hole cover.
    Fig 6: Disconnecting Connector From Fuel Sub Level Sensor
    G03584416Courtesy of SUBARU OF AMERICA, INC.
  9. Disconnect connector from fuel sub level sensor.
    Fig 7: Removing Service Hole Cover
    G03584417Courtesy of SUBARU OF AMERICA, INC.
  10. Disconnect fuel jet pump hose.
    Fig 8: Disconnecting Fuel Jet Pump Hose
    G03584418Courtesy of SUBARU OF AMERICA, INC.
  11. Remove bolts which install fuel sub level sensor on fuel tank.
    Fig 9: Removing Bolt
    G03584419Courtesy of SUBARU OF AMERICA, INC.
  12. Remove fuel sub level sensor.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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