Subaru Legacy IV Petrol, 2005 Wagon.
I couldn't find any good instructions for replacing inside fuel tank fuel filter. That`s why i decided to make one to help someone else who is also searching instructions for doing it by himself. A job was a bit complicated without a proper advice and i do believe that most of the people are still ready to pay for a mechanic rather than smelling gas steam for few hours and get hands dirty with this.
I did bought my fuel filter from internet(Singapore) where i found what i was already looking for before, Japan made(Js Asakashi) spare part with a good price even after all the shipping costs and taxes. Career(DHL) did bring it to me on my front door in a few days from another side of the planet.
Oem part would be cost over three times more from our local Subaru dealer.
To make your job easy and comfortable drive your fuel level low as possible and let the car lay down overnight that fuel system pressure could drop low.
*This is not absolutely necessary, you can also do this job when the engine is still warm.
Also a workspace is recommendable to be well ventilated.
Remove both sides of backseat from brackets by lifting front of it, one side at time(2piece of brackets are mounted at both sides of seat and they might be very tight attached so just be brave and use power while lifting it).
Seat is still attached with hook from back of it. Get it off by lifting seat and pulling it forward.
To help your working, remove also the threshold list most behind plastic bracket. Remove another similar bracket as well from center/front edge of seat to get carpet aside.
Make sure that the engine is shut down. Remove passenger side fuel tank hatch underneath seat. Take the fuel pump wire off from connector and put away hatch far as possible.
(This step isn't necessary if the car has been rested overnight.)
Start the engine and let it run till it dies.
Remove petrol cap to get all the pressure out of fuelsystem.
Take the key away from ignition switch and disconnect the battery terminals.
Remove the fuel hoses and put those aside(make sure that you remember where the hoses so post to go when putting all together, so mark the hoses if necessary).
Open the fuel tank hatch nuts(8pieces, 8mm nuts). Now you can lift a surrounding metal away from top of the fuel assembly.
To get the fuel assembly lifted up from the fuel tank without breaking it`s rubber seal you have to crack the seal carefully without breaking it. Usually it`s a bit sticked to fuel tank edge while been pressed by 8mm nuts(you can use a screw driver for this).
*At this stage the fuel may slosh/drain because a unit`s base is usually full of fuel ! ! !
Now start lifting the fuel assembly carefully and slowly upwards from the fuel tank. There is a fuel level sensor in a base of fuel assembly. Be careful not brake the sensor during lifting an assembly.
After you accomplished to get the fuel assembly out of the fuel tank, if there is a possibility try to pour the fuel out from unit example in a bowl. Lift the unit on to clean surface(eg. The rag on).
*Take a picture from the fuel assembly or mark all the parts that you remember where wires/hoses so post to go when putting all together.
Start extracting the fuel assembly by removing the fuel level sensor wire between unit and a base of it. Next crank the white plastic clamps side of the unit and pull at the same time unit and it`s base apart from each other. A fuel assembly and it`s base may be very tight together, so just be brave and use your power to get it separated.
After you have got parts separated just put a base of it away. Next you got to separate a unit from filter.
Remove fuel pump wire from both of ends and in addition the ground wire.
Remove fuel hose clamps from base of the fuel filter(DO NOT remove hoses from unit, just remove 2pieces of fuel hose clamps from a base of filter).
After that, you have to remove springs and a pin what keeps tension between the filter and the unit. In another spring there is a cotter pin what keeps parts together. A unit and a filter does move relative to each other with springs. Stretch the unit together with filter when you can see in a base of filter in a another spring the metal pin what is keeping parts together. Remove the pin by cranking it(MAKE SURE that the cotter pin will not lose).
Now the unit does get loosen from the filter easy by just pulling them apart from each other.
Remove 3pieces of small rubber seals from the old filter by cranking and put those in to a new one. Put the old filter away.
Put the assemble parts back together in a reverse order with a new fuel filter.
Double check the fuel assembly after you have put it back together that everything are correctly as they were before with old filter. After you are sure that fuel assembly is correctly put together you can install it back in the fuel tank.
After you have installed everything as they were before, closed the petrol cap and installed the battery terminals, before starting the engine let the key be in ignition switch with acc mode about 10 seconds before firing that the fuel pump has time to get pressure back in to fuel system.
If the car won`t start on a first time, don`t get worried. Sometimes fuel pressure takes a bit time to get back.
WAIT few more seconds on acc mode before a new try and the engine should start normally.
****Congratiolations during the job you have just killed about 20000 brain cells while smelling gas steam and you have accomplished a job what takes about 15 minutes in a oldskool car where the fuel filter is located under the hood. =) <3 engineering innovations.
Sorry for the bad english! =)