2005 Subaru Baja Base, StandardFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Removal

  1. Set vehicle on the lift.
  2. Release fuel pressure. < Ref. to , RELEASING OF FUEL PRESSURE , OPERATION, Fuel. >
  3. Drain fuel from fuel tank. < Ref. to , DRAINING FUEL , OPERATION, Fuel. >
  4. Remove holder clip which secures fuel tank cord on bracket.
    Fig 1: Removing Holder Clip Securing Fuel Tank Cord On Bracket
    G03748125Courtesy of SUBARU OF AMERICA, INC.
  5. Disconnect connector of fuel tank cord to rear harness.
    Fig 2: Disconnecting Fuel Tank Cord To Rear Harness Connector
    G03748126Courtesy of SUBARU OF AMERICA, INC.
  6. Push grommet which holds fuel tank cord on service hole cover into body side.
    Fig 3: Pushing Grommet Holding Fuel Tank Cord On Service Hole Cover
    G03748127Courtesy of SUBARU OF AMERICA, INC.
  7. Using ST, separate quick connector of fuel delivery (A) and return hose (B).< Ref. to , REMOVAL , Fuel Delivery, Return and Evaporation Lines. >

    ST 42099AE000 CONNECTOR REMOVER

    Fig 4: Separating Fuel Delivery Quick Connector And Return Hose Using Special Tool
    G03748128Courtesy of SUBARU OF AMERICA, INC.
  8. Remove parking brake cable.
    1. Remove console box. REMOVAL , Console Box . >
    2. Remove parking brake bracket and disconnect parking brake cable from equalizer. < Ref. to REMOVAL , Parking Brake Cable. >
  9. Remove pipe protector.
    Fig 5: Removing Pipe Protector
    G03748129Courtesy of SUBARU OF AMERICA, INC.
  10. Using ST, separate quick connector of evaporation pipe. < Ref. to , REMOVAL , Fuel Delivery, Return and Evaporation Lines. >

    ST 42099AE000 CONNECTOR REMOVER

    Fig 6: Separating Evaporation Pipe Quick Connector Using Special Tool
    G03748130Courtesy of SUBARU OF AMERICA, INC.
  11. Remove wheel nuts from rear wheels.
  12. Lift-up the vehicle.
  13. Remove rear wheel.
  14. Remove front side fuel tank cover.
    Fig 7: Removing Front Side Fuel Tank Cover
    G03748131Courtesy of SUBARU OF AMERICA, INC.
  15. 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: Separating Rear Exhaust Pipe And Center Exhaust Pipe
      G03748132Courtesy 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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