2005 Subaru Outback RFACTORY 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
    G03830299Courtesy of SUBARU OF AMERICA, INC.
  6. Disconnect the connector from fuel pump.
    Fig 2: Disconnecting Connector From Fuel Pump
    G03830300Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the connectors (A) and clips (B).
    Fig 3: Removing Connectors And Clips
    G03830301Courtesy 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: Removing Service Hole Cover Bolts
    G03830302Courtesy 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: Identifying Connectors
    G03830303Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the trunk room trim. (Sedan model) < Ref. to REMOVAL , Trunk Room Trim. >
  12. Remove the rear quarter trim. (Wagon model) < Ref. to WAGON MODEL , REMOVAL, Rear Quarter Trim. >
  13. Remove the pipe protector.
    Fig 6: Removing Pipe Protector
    G03830304Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the grommet and disconnect the quick connector of evaporation pipe. < Ref. to , REMOVAL , Fuel Delivery, Return and Evaporation Lines. >
    Fig 7: Removing Grommet
    G03830305Courtesy 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 Rear Brake Hose Bolt
    G03830306Courtesy 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
    G03830307Courtesy 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
    G03830308Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the bolts which install the parking brake cable clamp.
    Fig 11: Removing Parking Brake Cable Clamp Bolt (1 Of 2)
    G03830309Courtesy 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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