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HOMESERVICE MANUALSSUBARU2004OUTBACK BASE, 4D WAGON, EJ251, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCEENGINE CONTROL SYSTEMSFUEL INJECTION (FUEL SYSTEMS) (H4SO)FUEL TANKREMOVAL
2004 Subaru Outback Base, 4D Wagon, EJ251, Standard

Fuel Tank: Removal

2004 Subaru Outback Base, 4D Wagon, EJ251, StandardSECTION Removal
  1. Set vehicle on the lift.
  2. Release fuel pressure. Refer to RELEASING OF FUEL PRESSURE , OPERATION, Fuel.
  3. Drain fuel from fuel tank. Refer to DRAINING FUEL , OPERATION, Fuel.
  4. Remove holder clip which secures fuel tank cord on bracket.
    Fig 1: Removing Holder Clip Which Secures Fuel Tank Cord On Bracket
    G00898863Courtesy 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
    G00898864Courtesy of SUBARU OF AMERICA, INC.
  6. Push grommet which holds fuel tank cord on service hole cover into body side.
    Fig 3: Removing Grommet
    G00898865Courtesy of SUBARU OF AMERICA, INC.
  7. Using ST, separate quick connector of fuel delivery (A) and return hose (B). Refer to REMOVAL , Fuel Delivery, Return and Evaporation Lines.

    ST 42099AE000:  CONNECTOR REMOVER

    Fig 4: Removing Quick Connector Of Fuel Delivery & Return Hose
    G00898866Courtesy of SUBARU OF AMERICA, INC.
  8. Remove parking brake cable.
    1. Remove console box. Refer to REMOVAL , Console Box.
    2. Remove parking brake bracket and disconnect parking brake cable from equalizer. Refer to REMOVAL & INSTALLATION , Parking Brake Cable.
  9. Remove trunk trim. (Sedan model). Refer to REMOVAL , Trunk Trim.
  10. Remove rear quarter lower trim. (Wagon model). Refer to REMOVAL , Rear Quarter Trim
  11. Remove pipe protector.
    Fig 5: Removing Pipe Protector
    G00898867Courtesy of SUBARU OF AMERICA, INC.
  12. Using ST, separate quick connector of evaporation pipe. Refer to REMOVAL , Fuel Delivery, Return and Evaporation Lines.

    ST 42099AE000:  CONNECTOR REMOVER

    Fig 6: Removing Quick Connector Of Evaporation Pipe
    G00898868Courtesy 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 7: Removing Front Side Fuel Tank Cover
    G00898869Courtesy 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 and center exhaust pipe.
      Fig 8: Removing Rear Exhaust Pipe & Center Exhaust Pipe
      G00898870Courtesy of SUBARU OF AMERICA, INC.
    2. Remove left and right rubber cushions.
      CAUTION: Be careful not to pull down muffler. 
RENDER: 1.0x

NO RELATED

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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.