2005 Subaru Outback RFACTORY OEM SERVICE PROCEDURE

Fuel Sub Level Sensor: Removal

WARNING:
  • Place "NO FIRE" signs near the working area.
  • Be careful not to spill fuel on the floor.
  1. Drain fuel. < Ref. to , DRAINING FUELΒ , PROCEDURE, Fuel. >
  2. Remove the rear seat.
  3. Remove the service hole cover.
    1. Remove the bolts (A).
    2. Push the grommet (B) down under the body and remove the service hole cover.
    Fig 1: Identifying Bolt And Grommet
    G03830362Courtesy of SUBARU OF AMERICA, INC.
  4. Disconnect the connector from fuel sub level sensor.
    Fig 2: Disconnecting Connector From Fuel Sub Level Sensor
    G03830363Courtesy of SUBARU OF AMERICA, INC.
  5. Disconnect the quick connector and then disconnect the fuel delivery hose, return hose and jet pump hose. < Ref. to , REMOVALΒ , Fuel Delivery, Return and Evaporation Lines. >
  6. Remove the nuts and bolts which install the fuel sub level sensor on fuel tank.
    Fig 3: Disconnecting Fuel Delivery, Return And Jet Pump Hose
    G03830364Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the fuel sub level sensor.
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:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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