Subaru Legacy III (2000-2003 year). Manual - part 40

FU(H4SO)-62

FUEL INJECTION (FUEL SYSTEMS)

FUEL PUMP

22.Fuel Pump

A: REMOVAL 

WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill fuel on the floor.

NOTE:
The fuel pump assembly consists of fuel pump and
fuel level sensor.
1) Release the fuel pressure. <Ref. to FU(H4SO)-
48, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel filler flap lid, and then remove the
fuel filler cap.
3) Disconnect the ground cable from battery.

4) Lift-up the vehicle.
5) Remove the protector RH (Front).

6) Drain the fuel from fuel tank. Set a container un-
der the vehicle, and then remove the drain plug
from fuel tank.

7) Tighten the fuel drain plug, and then install the
protector RH (Front).

Tightening torque:

26 N·m (2.65 kgf-m, 19.2 ft-lb)

Tightening torque:

18 N·m (1.8 kgf-m, 13.0 ft-lb)

8) Raise the rear seat, and then turn the floor mat
up.
9) Remove the access hole lid.

10) Disconnect the connector from fuel pump.

FU-00009

FU-00443

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FU(H4SO)-63

FUEL INJECTION (FUEL SYSTEMS)

FUEL PUMP

11) Move the clips, and then disconnect the jet
pump hose (C).
12) Disconnect the quick connector, and then dis-
connect the fuel delivery hose (A) and return hose
(B). <Ref. to FU(H4SO)-70, REMOVAL, Fuel Deliv-
ery, Return and Evaporation Lines.>

13) Remove the nuts which install fuel pump as-
sembly onto fuel tank.

14) Take off the fuel pump assembly from fuel tank.

B: INSTALLATION

Install in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure the sealing portion is free from fuel or
foreign particles  before installation.
(3) Tighten the nuts in alphabetical sequence
shown in the figure to specified  torque.

Tightening torque:

5.9 N·m (0.6 kgf-m, 4.3 ft-lb)

C: DISASSEMBLY

1) Remove the fuel pump and pump holder.

NOTE:
When disassembling the pump holder, be careful
as it is installed with two pawls.

2) Disconnect the connector from fuel pump.

D: ASSEMBLY

Assemble in the reverse order of disassembly.

E: INSPECTION

Connect the lead harness to connector terminal of
fuel pump, and then apply  battery power supply to
check whether the pump operate.

WARNING:
• Wipe off the fuel completely.
• Keep the battery as far apart from fuel pump
as possible.
• Be sure to turn the battery supply ON and
OFF on the battery  side.
• Do not run the fuel pump for a long time un-
der non-load condition.

FU-00490

( A )

( B )

( C )

FU-00491

FU-00492

( A )

( B )

( C )

( D )

( E )

( F )

( G )

( I )

( J )

( H )

FU-00678

FU-00679

FU-00495

5 6
3 4
1 2

FU(H4SO)-64

FUEL INJECTION (FUEL SYSTEMS)

FUEL LEVEL SENSOR

23.Fuel Level Sensor

A: REMOVAL

WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill fuel on the floor.

NOTE:
The fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(H4SO)-62, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.

3) Pushing the pawls with a screwdriver, remove
the fuel meter unit by pulling it downwards.

NOTE:
Replace the fuel filter pawls with new ones as they
might brake when removed.

B: INSTALLATION

Install in the reverse order of removal.

WARNING:
• Ground cable must be connnected.
• Spark may occur and ignite if fuel is nearby.

FU-00680

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FU(H4SO)-65

FUEL INJECTION (FUEL SYSTEMS)

FUEL SUB LEVEL SENSOR

24.Fuel Sub Level Sensor

A: REMOVAL

WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill fuel on the floor.
1) Disconnect the ground cable from battery.

2) Lift-up the vehicle.
3) Remove the front side fuel tank cover.

4) Drain fuel from fuel tank. Set a container under
the vehicle, and then remove the drain plug from
fuel tank.

5) Tighten the fuel drain plug and install the protec-
tor RH (Front).

Tightening torque:

26 N·m (2.65 kgf-m, 19.2 ft-lb)

Tightening torque:

18 N·m (1.8 kgf-m, 13.0 ft-lb)

6) Remove the rear seat.
7) Remove the service hole cover.

8) Disconnect the connector from fuel sub level
sensor.

FU-00009

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