2005 Subaru Outback Limited, 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 a lift.
  2. Release the fuel pressure.

    < Ref. to , RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel. >

  3. Drain fuel from the fuel tank.

    < Ref. to , DRAINING FUEL , PROCEDURE, Fuel. >

  4. Remove the rear seat.
  5. Remove the service hole cover from fuel pump.
    Fig 1: Removing Service Hole Cover From Fuel Pump
    G03827758Courtesy of SUBARU OF AMERICA, INC.
  6. Disconnect the connector from fuel pump.
    Fig 2: Disconnecting Connector From Fuel Pump
    G03827759Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the connector and clips (B).
    Fig 3: Removing Connector And Clips
    G03827760Courtesy of SUBARU OF AMERICA, INC.
  8. Remove the service hole cover from fuel sub level sensor.
    1. Remove the bolts (A).
    2. Push the grommet (B) down under the body and remove service hole cover.
    Fig 4: Push Grommet Down Under Body And Remove Service Hole Cover
    G03827761Courtesy of SUBARU OF AMERICA, INC.
  9. Disconnect the connector (A) from fuel sub level sensor.
  10. Disconnect the quick connector from the fuel delivery (B) and return hose (C). < Ref. to , REMOVAL , Fuel Delivery, Return and Evaporation Lines. >
    Fig 5: Disconnecting Quick Connector From Fuel Delivery And Return Hose
    G03827762Courtesy of SUBARU OF AMERICA, INC.
  11. Remove trunk room trim. (Sedan model) < Ref. to REMOVAL , Trunk Room Trim. >
  12. Remove rear quarter trim. (Wagon model) < Ref. to WAGON MODEL , REMOVAL, Rear Quarter Trim. >
  13. Remove pipe protector.
    Fig 6: Removing Pipe Protector
    G03827763Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the grommet, and then disconnect the quick connector of evaporation pipes. < Ref. to , REMOVAL , Fuel Delivery, Return and Evaporation Lines. >
    Fig 7: Removing Grommet, And Disconnecting Quick Connector Of Evaporation Pipes
    G03827764Courtesy of SUBARU OF AMERICA, INC.
  15. Remove the rear wheels.
  16. Remove the bolts which secure the rear brake hose installation bracket.
    Fig 8: Removing Bolts Securing Rear Brake Hose Installation Bracket
    G03827765Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the rear brake caliper and tie it to the vehicle body side.
    Fig 9: Removing Rear Brake Caliper
    G03827766Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the parking brake cable from parking brake assembly. < Ref. to REMOVAL , Parking Brake Assembly (Rear Disc Brake). >
  19. Lift-up the vehicle.
  20. Remove the rear exhaust pipe.

    < Ref. to REMOVAL , Rear Exhaust Pipe. >

  21. Remove the propeller shaft. < Ref. to REMOVAL , Propeller Shaft. >
  22. Remove the heat shield cover.
  23. Disconnect the connector from rear ABS wheel speed sensor.
    Fig 10: Disconnecting Connector From Rear ABS Wheel Speed Sensor
    G03827767Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the bolts which install the parking brake cable clamp.
    Fig 11: Removing Bolts Which Install Parking Brake Cable Clamp (1 Of 2)
    G03827768Courtesy of SUBARU OF AMERICA, INC.
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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