Subaru Legacy IV (2008 year). Service manual - part 243

FU(H4DOTC)-75

Fuel Filter

FUEL INJECTION (FUEL SYSTEMS)

32.Fuel Filter

A: REMOVAL

WARNING:
Place “NO OPEN FLAMES” signs near the
working area.

CAUTION:
• Be careful not to spill fuel.
• If the fuel gauge indicates that two thirds or
more of the fuel is remaining, be sure to drain
fuel before starting work to avoid the fuel to
spill.
• Be careful not to drop or apply any impact to
the fuel pump during work. This may deterio-
rate its performance.

NOTE:
The fuel filter is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(H4DOTC)-70, REMOVAL, Fuel Pump.>
2) Remove the fuel level sensor and fuel tempera-
ture sensor. <Ref. to FU(H4DOTC)-72, REMOVAL,
Fuel Level Sensor.>
3) Disconnect the pump assembly connector from
the sub tank bracket assembly.

4) Cut off the tab holders connecting the sub tank
bracket assembly and the sub tank in four loca-
tions, and separate the two.

CAUTION:
Be careful not to damage the sub tank.

NOTE:
If the O-ring is remaining on the subtank, remove.

5) Disconnect the fuel piping connector from the
fuel filter assembly in two locations.

6) Push to compress the fuel filter assembly in the
direction of the arrow, remove clip (A), and sepa-
rate the sub tank bracket assembly and the fuel fil-
ter assembly.

CAUTION:
When separating the sub tank bracket assem-
bly and the fuel filter assembly, be careful not
to damage the ground wire.

7) Disconnect the connector from the pump assem-
bly.

FU-03849

FU-03850

FU-03851

FU-03852

(A)

FU-03853

FU(H4DOTC)-76

Fuel Filter

FUEL INJECTION (FUEL SYSTEMS)

8) Lift the two tab holders connecting the pump as-
sembly to the fuel filter using a flat tip screwdriver
(with a shaft diameter of approx. 3 mm (0.12 in)),
etc., and separate the fuel filter and pump assem-
bly.

CAUTION:
• To prevent damaging the tabs of the pump
assembly, wrap the tip of flat tip screwdriver
(A), etc. with tape (B).

• Be careful not to drop or apply any impact to
the pump assembly.

NOTE:
If the spacer and o-ring is remaining on the pump
assembly, remove these.

B: INSTALLATION

1) Assemble o-ring (A) and spacer (B) to the fuel
pump, and attach the pump assembly to the fuel fil-
ter.

NOTE:
• Use new O-rings (8 mm (0.31 in) inner diameter).
• Use a new spacer.
• Apply gasoline to the o-ring.
• Insert the pump assembly until a click is heard.

2) Connect the connector to the pump assembly.

FU-03929

(B)

(A)

FU-03927

(A)

(B)

FU-03859

FU-03853

FU(H4DOTC)-77

Fuel Filter

FUEL INJECTION (FUEL SYSTEMS)

3) Attach spring (A) to the metal rod of the sub tank
bracket assembly, and assemble the fuel filter as-
sembly.

NOTE:
Use a new spring.

4) Push the fuel filter assembly in the direction of
the arrow to compress, and attach clip (A).

NOTE:
Use a new clip.

5) Connect the fuel piping connector to the fuel fil-
ter assembly.

NOTE:
• Use new O-rings.
• Apply gasoline to the o-ring.
• The O-rings of the black and white connectors
are identified by a difference in diameter. Be careful
not to confuse the two during assembly.

O-ring inner diameter:

Black connector O-ring [Approx. 7 mm (0.28 in)]
White connector O-ring [Approx. 8 mm (0.31 in)]

6) Attach the O-ring (A) to the fuel filter assembly,
and attach the subtank to the sub tank bracket as-
sembly.

NOTE:
• Use new O-rings (8 mm (0.31 in) inner diameter).
• Apply gasoline to the o-ring.
• Insert the pump assembly until a “pop” is heard.

FU-03860

(A)

(A)

FU-03861

(A)

FU-03851

FU-03862

(A)

FU(H4DOTC)-78

Fuel Filter

FUEL INJECTION (FUEL SYSTEMS)

7) Replace the cushion on the rear face of the sub
tank with a new cushion.

8) Connect the pump assembly connector to the
sub tank bracket assembly.

9) Install the fuel level sensor and fuel temperature
sensor. <Ref. to FU(H4DOTC)-72, INSTALLA-
TION, Fuel Level Sensor.> <Ref. to EC(H4DOTC)-
13, INSTALLATION, Fuel Temperature Sensor.>
10) Install the fuel pump assembly. <Ref. to
FU(H4DOTC)-71, INSTALLATION, Fuel Pump.>

FU-03863

FU-03849