2002 Subaru Outback Base, 4D SedanFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Removal

  1. Set vehicle on the lift.
  2. Release fuel pressure. < Ref. to , RELEASING OF FUEL PRESSURE  , OPERATION, FUEL. >
  3. Drain fuel from fuel tank. < Ref. to , DRAINING FUEL  , OPERATION, FUEL. >
  4. Remove holder clip which secures fuel tank cord on bracket.
    Fig 1: Removing Holder Clip Securing Fuel Tank Cord On Bracket
    G03584298Courtesy of SUBARU OF AMERICA, INC.
  5. Disconnect connector of fuel tank cord to rear harness.
    Fig 2: Disconnecting Connector Of Fuel Tank Cord To Rear Harness
    G03584299Courtesy of SUBARU OF AMERICA, INC.
  6. Push grommet which holds fuel tank cord on service hole cover into body side.
    Fig 3: Pushing Grommet
    G03584300Courtesy of SUBARU OF AMERICA, INC.
  7. Separate quick connector of fuel delivery (A) and return hose (B). < Ref. to , REMOVAL  , Fuel Delivery, Return and Evaporation Lines. >
    Fig 4: Separating Quick Connector Of Fuel Delivery And Return Hose
    G03584301Courtesy of SUBARU OF AMERICA, INC.
  8. Remove parking brake cable.
    1. Remove console box console. < Ref. to REMOVAL , Console Box. >
    2. Remove parking brake bracket and disconnect parking brake cable from equalizer. < Ref. to REMOVAL & INSTALLATION . >
      Fig 5: Removing Parking Brake Bracket And Disconnecting Parking Brake Cable From Equalizer
      G03584302Courtesy of SUBARU OF AMERICA, INC.
  9. Remove trunk trim. (Sedan model)

    < Ref. to REMOVAL , Trunk Trim. >

  10. Remove rear quarter lower trim. (Wagon model)

    < Ref. to WAGON , REMOVAL, Rear Quarter Trim. >

  11. Remove pipe protector.
    Fig 6: Removing Pipe Protector
    G03584303Courtesy of SUBARU OF AMERICA, INC.
  12. Separate quick connector of evaporation pipe (A). < Ref. to , REMOVAL  , Fuel Delivery, Return and Evaporation Lines. >
    Fig 7: Separating Quick Connector Of Evaporation Pipe
    G03584304Courtesy of SUBARU OF AMERICA, INC.
  13. Remove wheel nuts from rear wheels.
  14. Lift-up the vehicle.
  15. Remove rear wheel.
  16. Remove front side fuel tank cover.
    Fig 8: Removing Front Side Fuel Tank Cover
    G03584305Courtesy of SUBARU OF AMERICA, INC.
  17. 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 front exhaust pipe.
      Fig 9: Separating Rear Exhaust Pipe From Front Exhaust Pipe
      G03584306Courtesy of SUBARU OF AMERICA, INC.
    2. Remove left and right rubber cushions.
      CAUTION: Be careful not to pull down muffler.
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:

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

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