Subaru 42012FE090 Fuel Tank Gas

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All repairs to the fuel tank or filler neck must be carried out by a professional who has experience in this critical and potentially dangerous work. Even after cleaning and flushing of the fuel system, explosive fumes can remain and ignite during repair of the tank. If the fuel tank is removed from the vehicle, it should not be placed in an area where sparks or open flames could ignite the fumes coming out of the tank. Be especially careful inside garages where a gas-type appliance is located, because it could cause an explosion.

The following procedure is much easier to perform if the fuel tank is empty. Remove the fuel tank filler cap to relieve fuel tank pressure. Relieve the fuel system pressure. Disconnect the cable from the negative battery terminal. Remove the rear seat and floor mat. Disconnect the electrical connector from the fuel pump/fuel level sending unit harness. Remove the sub-compartment fuel level sending unit access plate, and disconnect the fuel supply and return hose quick-connect fittings. Remove the center console and disconnect the parking brake cable from the equalizer. Remove the trim carpeting from the right side of the trunk (sedan models) or the rear quarter lower trim (wagon models). Remove the grommet and disconnect the EVAP line quick-connect fitting from the EVAP line that runs through the right front corner of the trunk/luggage compartment. Loosen the rear wheel lug nuts. Raise the vehicle and support it securely on jackstands. Remove the rear wheels. Remove the left and right covers from the front of the fuel tank. On 2007 and earlier models, remove the drain plug and drain the fuel from the right side of the fuel tank into an approved fuel container. To drain the left side of the tank on all models, remove the sub-compartment fuel level sending unit and siphon the fuel into an approved fuel container. To drain the right side of the tank on 2008 and later models, remove the fuel pump module. Remove the rear exhaust pipe and muffler. Remove the driveshaft. Disconnect the electrical connector from the ABS sensor. Remove the parking brake cable assembly. On models with rear drum brakes, disconnect the metal brake lines from the wheel cylinders. Plug the brake lines to prevent excess fluid leakage and the entry of contaminants. On models with rear disc brakes, remove the bolts that attach the rear brake hose clips, then remove the rear brake calipers and suspend them out of the way. Support the rear differential with a floor jack, placing a piece of plywood between the jack and the differential to protect the differential housing. Disconnect the lower ends of the rear shock absorbers from the rear knuckles. Remove the rear differential and rear subframe/suspension assembly. Remove the rear fuel tank covers. Disconnect the fuel filler neck hose and the fuel tank pressure sensor hose. Disconnect the air vent hose from the EVAP pipe assembly and disconnect the EVAP hose from the pressure control solenoid valve. Support the fuel tank. Remove the fuel tank strap bolts, then carefully lower the fuel tank, ensuring nothing remains connected. Installation is the reverse of removal. Tighten the fuel tank strap bolts.

Disconnect the quick-connect fittings for the fuel supply and return hoses.