2000 Subaru Outback Wagon Fuel Pump Assy Remove/Install - Subaru Outback - Subaru Outback Forums

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Old 09-05-2010, 12:43 PM   #1 (permalink)
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Default 2000 Subaru Outback Wagon Fuel Pump Assy Remove/Install

If I did this right (new member, first post), the following video shows the steps I took to remove and install the fuel pump assy of my 2000 OBW. Its not the greatest, but it might be helpfull to somebody.


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Last edited by Subawag; 09-05-2010 at 12:45 PM. Reason: Corrections
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Old 09-06-2010, 12:24 PM   #2 (permalink)
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That was awesome. Excellent & clear. Thank you.
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Old 09-06-2010, 02:38 PM   #3 (permalink)
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Yes, very nice!

Thank you, your wife, and your dog.
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Old 09-06-2010, 02:47 PM   #4 (permalink)
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Very helpful! Thanks.
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Old 09-06-2010, 06:52 PM   #5 (permalink)
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Very well done.

I was impressed by how clean everything underneath was, and how easily the screws and bolts seemed to come out on a 10 year old car, but then laughed when I saw that this was the second time the assembly was removed. Was it the same the first time? In any event, that doesn't detract from the usefulness of the step by step visual.

What was the problem that led to replacing the pump, and then the o-ring, and how did you narrow it down to the o-ring? I think this might make the video even more helpful overall.
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Old 09-07-2010, 11:49 PM   #6 (permalink)
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Default Plain OM Q&A

Q. Was it the same the first time?

A. Clean- No. The entire top of the assembly was a nice dirt/dust brown.
A. Easy screws and bolts- Yes. Nothing really gave me a problem, all was pretty easy. Even removing the hoses for the first time was simple.

Q. What was the problem that led to replacing the pump?

A. Wife got in the car to run some errands, and the car simply would not start. Turned over great, but acted as if it wasnt getting enough fuel. Fuel pump sounded very weak to me, so I went ahead and purchased a new one ($80 at NAPA). Installed it, crossed my fingers and "ta-da".

Q. ...and then the o-ring?

A. When I had the fuel pump assembly out the first time, I noticed the metal cap and o-ring didnt look right. The metal cap looked like it was cross-threaded and the o-ring was bulging out of one side. I thought I would just take the metal cap off, reset the o-ring, and re-attach the metal cap- WRONG! Apparently the o-ring has swollen over the years and this swelling was the reason for the bulging. Anyways, I got the o-ring off but could not get it back on, so I went ahead and finished the fuel pump install and put everything back together (minus 1 o-ring). With the new fuel pump, the car ran fine, but took 2-3 attemps to get started if it sat for more than 15 minutes.

Q. How did you narrow it down to the o-ring?

A. That was the only thing that I removed that wouldnt go back in its place. Sucks to put something back together only to have a part left over. Anyways, I wasnt sure if the car was even going to run without that o-ring in place, but I gave it a shot and lucked out.

Ideally, I should have replaced the o-ring while I had the assembly out for the new fuel pump, but I just wanted to get her home first.

Hope this answers your questions...

Take care...
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Old 12-16-2010, 02:20 PM   #7 (permalink)
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Default Gas smell when tank is full

Thanks a million for your post. I'm going to have to pull that assembly this weekend to replace the seal between the assembly and the fuel tank. Mine seeps a little bit when the tank is more than 3/4 full and the gas smell is terrible. Seeing your removal/replacement takes much of the mystery away from the project. Thanks again!
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Old 12-17-2010, 06:47 PM   #8 (permalink)
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@juhlik

If you havent already purchased the seal, you might check to make sure its not something simple like loose bolts that hold down the assembly bracket. Just food for thought.

Good luck, and happy holidays.

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Old 12-23-2010, 10:28 AM   #9 (permalink)
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This is definitely a helpful post. Thanks for the video.
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Old 09-17-2011, 02:00 PM   #10 (permalink)
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Default Fuel pump assembly parts - oring and cap

I saw your video and thought it was great. Thank you. I too had the same problem and replaced the fuel pump only to find that I also needed to replace the o-ring. After a long search, I found the o-ring at a hydraulics place. None of the auto parts stores here carry a fuel rated o-ring.

Now to my question. The metal cap that holds the o-ring in place is actually the cause of my problem. The one of the tabs that latches the cap to the assembly is broken so that with any pressure, it pops off. Where might I find a replacement cap? I have searched for diagrams so that I know the name of the part, but could not find any with part names. I am trying to avoid having to replace the entire assembly because a small part that should be replaceable. Any help would be appreciated. Thanks.
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