2004 Subaru Baja Turbo, AutomaticFACTORY OEM SERVICE PROCEDURE

Fuel Filler Pipe: Removal: Notes

WARNING:
  • Place "NO FIRE" signs near the working area. 
  • Be careful not to spill fuel on the floor. 
  1. Set the vehicle on the lift.
  2. Disconnect battery ground cable.
    Fig 1: Disconnecting Battery Ground Cable
    G00928949Courtesy of SUBARU OF AMERICA, INC.
  3. Open fuel filler flap lid and remove filler cap.
  4. Remove screws holding packing in place.
    Fig 2: Removing Screws
    G00928950Courtesy of SUBARU OF AMERICA, INC.
  5. Lift-up the vehicle.
  6. Remove rear wheel nuts.
  7. Remove rear wheel.
    Fig 3: Removing Rear Wheel
    G00928951Courtesy of SUBARU OF AMERICA, INC.
  8. Remove front right side fuel tank cover.
    Fig 4: Removing Front Right Side Fuel Tank Cover
    G00928952Courtesy of SUBARU OF AMERICA, INC.
  9. Drain fuel from fuel tank. Set a container under the vehicle and remove drain plug from fuel tank.
    Fig 5: Removing Drain Plug From Fuel Tank
    G00928953Courtesy of SUBARU OF AMERICA, INC.
  10. 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
    G00928954Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    18 N.m (1.8 kgf-m, 13.0 ft-lb) 

    Fig 7: Tightening Front Right Side Fuel Tank Cover
    G00928955Courtesy of SUBARU OF AMERICA, INC.
  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) 

    1. Separate rear exhaust pipe from center exhaust pipe.
      Fig 8: Separating Rear Exhaust Pipe From Center Exhaust Pipe
      G00928956Courtesy 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.