Replacing 06 Wrx Fuel Lines: A Step-By-Step Guide

Changing the fuel lines of a 2006 WRX is a complex task that requires careful attention to safety. The fuel filter is located inside the tank, and while it is technically a non-serviceable item, it may need to be changed if there are signs of clogging. Before beginning any work, it is important to ensure the fuel system is fully depressurised. This can be done by disconnecting the wiring harness from the fuel pump or by disconnecting the fuel pump relay. The next steps involve removing the fuel tank cover and pump assembly, disconnecting the electrical connector and feed hose, and carefully lifting away the assembly. It is crucial not to drop anything into the tank during this process. The old fuel pump can then be removed from its rubber cradle, and a new one can be installed, taking care to secure the rubber hose properly. Finally, the process is reversed to refit the new pump, ensuring that all connections are tight to prevent leaks.

Removing the fuel tank

To remove the fuel tank from a 2006 WRX, follow these steps:

Begin by unscrewing the fuel cap and disconnecting the green plug behind the passenger footwell trim. Crank the motor for one minute. Disconnect the battery and open all the doors. Fold the rear seats and remove the scrolling trunk cover. Remove all the cargo area floor sections piece by piece; there are several plastic snaps, so take care not to break them. Remove the donut. On the passenger side, directly behind the folded seat, there is an ovalised metal cover. Remove this and the foam beneath it to expose the fuel lines.

Disconnect the electrical connector and the feed hose. The feed hose is the one with the plastic clip, closest to the front of the vehicle, and it will be pressurised with fuel. Use shop towels to cover the area and reach underneath to pop off the pressurised hose. Fuel will escape under pressure, so be sure to catch it with paper towels. Disconnect the two return/breather hoses. These may dribble a small amount of gasoline.

Unbolt the fuel tank cover/pump assembly. It is retained by a number of 8mm hex bolts. Push the hoses and electrical connector clear of the cover. Very carefully lift away the entire assembly, taking care not to bend anything. Finally, rotate the assembly to get the float and strainer clear of the tank.

Disconnecting the fuel pump

Firstly, ensure you have the necessary tools and safety equipment. Wear gloves and eye protection to shield yourself from any fuel spray or spillage. It is also important to work in a well-ventilated area to avoid inhaling fuel vapours.

Now, to the car. Begin by unscrewing the fuel cap and disconnecting the green plug behind the passenger footwell trim. Next, crank the engine for about one minute. Disconnect the battery and ensure all windows are up, especially if you are working outdoors.

Open all the doors and fold the rear seats. Remove the scrolling trunk cover and all the cargo area floor sections, piece by piece. You will encounter several plastic snaps; carefully remove them, trying not to break any.

Remove the donut. On the passenger side, directly behind the folded seat, there is an ovalised metal cover. Remove this and the foam underneath to expose the fuel lines.

Disconnect the electrical connector. You will also need to disconnect the feed hose, which is the one with the plastic clip closest to the front of the vehicle. It will still be pressurised with fuel, so have shop towels on hand to catch any spillage. Cover the area with towels, then reach under and pop off the pressurised hose.

Disconnect the two return/breather hoses as well. These may dribble a small amount of gasoline, so be prepared.

The next step is to unbolt the fuel tank cover/pump assembly. It is secured by several 8mm hex bolts. Push the hoses and electrical connector clear of the cover, and then carefully lift away the entire assembly. Take care not to bend anything. Finally, you will likely need to rotate it to get the float and strainer clear of the tank.

At this point, you have successfully disconnected the fuel pump and can proceed with changing the fuel lines. Remember to have a container ready to catch any fuel spillage and always work in a well-ventilated area to avoid inhaling fumes.

Depressurising the fuel system

Firstly, ensure that you have turned off your car and given it a couple of hours for the pressure to bleed off. This is a crucial safety measure as it will help prevent fuel from spraying out when you disconnect the fuel lines.

Next, locate the fuel pump. In a 1993 Legacy Turbo, for example, you can access the fuel pump by removing the rear seat and taking off the cover that protects it. Disconnect the wiring harness from the pump by removing the relevant cover. Alternatively, you can depressurise the system by disconnecting the fuel pump relay. In the aforementioned model, the fuel pump relay is located on the left side of the dashboard, up against the firewall, and has a green-coloured connector.

Once you have disconnected either the wiring harness or the fuel pump relay, crank the engine for about five seconds. If the engine starts, let it run until it dies, and then crank it a little more. This will ensure that the fuel system is fully depressurised.

Now, you can safely begin the process of changing the fuel lines. Remember to have a bunch of shop towels or paper towels on hand to catch any fuel that may leak or drip during the process.

Always exercise extreme caution when working with fuel systems, and if you are unsure about any steps, consult a qualified mechanic.

Removing the fuel dampers

To remove the fuel dampers, you will need to first disconnect the battery. If you are working outside, make sure your windows are up. Open all the doors and fold the rear seats. Remove the scrolling trunk cover and the cargo area floor sections piece by piece. There are several plastic snaps that you will need to remove. Be careful not to break them.

Next, you will need to remove the donut and the ovalized metal cover on the passenger side directly behind the folded seat. Remove the foam underneath to expose the fuel lines. Disconnect the electrical connector and the feed hose. The feed hose will still be pressurized with fuel, so use shop towels to cover the area and catch any fuel that escapes when you pop off the pressurized hose.

Now, disconnect the two return/breather hoses. These may dribble a small amount of gasoline, so be prepared to catch any drips with a container or paper towels. Once these are disconnected, you can remove the fuel tank cover/pump assembly by unbolting it. There will be several 8mm hex bolts holding it in place.

Carefully lift away the entire assembly, being careful not to bend anything. You may need to rotate it to get the float and strainer clear of the tank. Do not drop anything into the tank. Place a towel over the opening to stop excessive fumes from accumulating in your WRX.

Now that you have access to the fuel lines, you can proceed to remove the fuel dampers. This may involve cutting or detaching the dampers from the fuel lines, ensuring that you do not damage the lines themselves. It is important to work carefully and use the appropriate tools to avoid any damage to the fuel system.

Replacing the fuel hose

Step 1: Remove Pressure from the Fuel System

Before starting, ensure that there is no pressure in the fuel system. Wait a couple of hours after turning the car off, and all the pressure will bleed off. You can also disconnect the fuel pump and crank the car to suck the pressure out of the fuel system.

Step 2: Remove the Fuel Hose

Park your car on a level surface and engage the parking brake. Open the hood and locate the fuel hose. It is usually a silver or black canister located on the front inside corner of the front left strut tower in the engine bay. Place a drain pan or container underneath the fuel hose to catch any fuel that may spill. Loosen the clamp that secures the fuel hose to the fuel filter using a screwdriver or wrench. Gently pull the fuel hose off the fuel filter.

Step 3: Install the New Fuel Hose

Prepare the new fuel hose by cutting it to the appropriate length if necessary. Slide the new fuel hose onto the hard lines, making sure that the clamps are installed on the rubber hoses before pushing them over the hard line. Tighten the clamps securely, using a screwdriver or wrench.

Step 4: Reattach the Fuel Hose

Reattach the fuel hose to the fuel filter, ensuring that the connection is secure and there are no leaks. Reconnect the fuel pump and crank the engine to build up pressure in the fuel system. Check for any leaks around the fuel hose and tighten the clamps further if necessary.

Step 5: Test the System

Start the engine and check for any leaks or unusual noises. Let the engine run for a few minutes to ensure that the fuel system is functioning properly. If there are no issues, you have successfully replaced the fuel hose!

Frequently asked questions