2004 Subaru Forester X, StandardFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Removal

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. Release the fuel pressure. Refer to RELEASING OF FUEL PRESSURE , OPERATION, Fuel.
  3. Drain the fuel from the fuel tank. Refer to DRAINING FUEL , OPERATION, Fuel.
  4. Remove the rear seat.
  5. Disconnect the connector (A) of fuel tank cord to the rear harness.
  6. Push the grommet (B) which holds the fuel tank cond on the floor panel into under the body.
    Fig 1: Pushing Grommet Which Holds Fuel Tank Cond On Floor Panel Into Under Body
    G00994889Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the rear crossmember. Refer to REMOVAL , Rear Crossmember.
  8. Loosen the clamp, and disconnect the evaporation hose from the canister.
    Fig 2: Disconnecting Evaporation Hose From Canister
    G00994890Courtesy of SUBARU OF AMERICA, INC.
  9. Disconnect the connector from the pressure control solenoid valve.
  10. Disconnect the connector from the drain valve.
    Fig 3: Disconnecting Connector From Drain Valve
    G00994891Courtesy of SUBARU OF AMERICA, INC.
  11. Loosen the clamp and disconnect the fuel filler hose (A) and evaporation hose (B) from the fuel filler pipe.
    Fig 4: Disconnecting Fuel Filler Hose & Evaporation Hose From Fuel Filler Pipe
    G00994892Courtesy of SUBARU OF AMERICA, INC.
  12. Move the clips, and disconnect the quick connector. Refer to REMOVAL , Fuel Delivery, Return and Evaporation Lines.
  13. Disconnect the fuel hoses.
    Fig 5: Disconnecting Fuel Hoses
    G00994893Courtesy of SUBARU OF AMERICA, INC.
  14. Support the fuel tank with transmission jack, remove the band mounting bolts and dismount the fuel tank from the vehicle.
    WARNING: A helper is required to perform this work. 
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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