2004 Subaru Forester XT, AutomaticFACTORY 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. < Ref. to RELEASING OF FUEL PRESSURE  . >
  3. Drain the fuel from the fuel tank. < Ref. to DRAINING 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 con. on the floor panel into under the body.
    Fig 1: Identifying Fuel Tank Cord
    G00966400Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the rear crossmember. < Ref. to REMOVAL , Rear Crossmember . >
  8. Loosen the clamp, and disconnect the evaporation hose from the canister.
    Fig 2: Identifying Evaporation Hose
    G00966401Courtesy 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: Identifying Drain Valve
    G00966402Courtesy 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: Identifying Fuel Filler Hose And Evaporation Hose
    G00966403Courtesy of SUBARU OF AMERICA, INC.
  12. Move the clips, and disconnect the quick connector. < Ref. to REMOVAL , Fuel Delivery, Return and Evaporation Lines . >
  13. Disconnect the fuel hoses.
    Fig 5: Identifying Fuel Hoses
    G00966404Courtesy of SUBARU OF AMERICA, INC.
  14. Support the fuel tank with transmission jack, remove the bolts from bands 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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