2004 Subaru Outback L.L. Bean EditionFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Removal

  1. Set vehicle on the lift.
  2. Release fuel pressure. Refer to FUEL .
  3. Drain fuel from fuel tank. Refer to FUEL .
  4. Remove holder clip which secures fuel tank cord on bracket.
    Fig 1: Removing Holder Clip
    G00897314Courtesy of SUBARU OF AMERICA, INC.
  5. Disconnect connector of fuel tank cord to rear harness.
    Fig 2: Disconnecting Fuel Tank Cord Connector
    G00897315Courtesy of SUBARU OF AMERICA, INC.
  6. Push grommet which holds fuel tank cord on service hole cover into body side.
    Fig 3: Pushing Fuel Tank Cord Grommet
    G00897316Courtesy of SUBARU OF AMERICA, INC.
  7. Using ST, separate quick connector of fuel delivery (A) and return hose (B). Refer to FUEL DELIVERY, RETURN AND EVAPORATION LINES .

    ST 42099AEOOO CONNECTOR REMOVER

    Fig 4: Separating Quick Connector Of Fuel Delivery
    G00897317Courtesy 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.
      Fig 5: Disconnecting Parking Brake Cable From Equalizer
      G00897318Courtesy of SUBARU OF AMERICA, INC.
  9. Remove trunk trim. (Sedan model) Refer to REMOVAL , Trunk Trim.
  10. Remove rear quarter lower trim.

    Refer to REMOVAL , Rear Quarter Trim.

  11. Remove pipe protector.
    Fig 6: Removing Pipe Protector
    G00897319Courtesy of SUBARU OF AMERICA, INC.
  12. Using ST, separate quick connector of evaporation pipe (A). Refer to FUEL DELIVERY, RETURN AND EVAPORATION LINES .

    ST 42099AEOOO CONNECTOR REMOVER

    Fig 7: Separating Evaporation Pipe Quick Connector
    G00897320Courtesy 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
    G00897321Courtesy 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 center exhaust pipe.
      Fig 9: Separating Rear Exhaust Pipe
      G00897322Courtesy 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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