Replacing Fuel Pump In 1999 Subaru Forester: Step-By-Step Guide

Changing the fuel pump on a 1999 Subaru Forester is a complex task that requires a range of tools and mechanical knowledge. The fuel pump is located inside the fuel tank and supplies pressurised gasoline to the engine. While it is possible to replace the fuel pump yourself, it is recommended to hire a professional mechanic due to the risks associated with handling gasoline. This job typically costs between $200 and $600, including labour, and can be completed in a few hours.

Tools and equipment needed

To change the fuel pump on a 1999 Subaru Forester, you will need a range of tools and equipment.

Firstly, you will need various sizes of sockets and extensions, including 8mm, 10mm, and 12mm sockets. You will also need a range of screwdrivers, including Phillips-head and flat-head types, as well as a pair of needlenose pliers. It is also recommended to have a respirator to avoid inhaling fumes.

Additionally, you will need a container to catch the fuel when you drain the fuel tank. It is also suggested to have a new rubber gasket or to clean the existing one thoroughly. A sealant may also be required to create an airtight seal.

For the actual fuel pump replacement, you will need the new fuel pump and strainer bag, as well as any other replacement parts you wish to install.

Please note that this list may not be exhaustive, and it is always a good idea to have a range of basic tools on hand for any unexpected requirements during the repair process.

Removing seats and clutter

To remove the seats and clutter from your 1999 Subaru Forester to access the fuel pump, follow these steps:

Firstly, ensure you have a clean and well-lit workspace, free of clutter and obstructions. Move your vehicle into the chosen workspace so that you can easily reach all necessary parts.

Next, you will need to remove the rear seats. Start by removing the seat covers and setting them aside. Then, use a screwdriver to remove the bolts holding the back and bottom cushions in place. Set the bolts aside and remove the cushions. Clean the area where the seat was with a cloth to remove any dirt or debris.

Now that the cushions are removed, you will need to disconnect the seat belt mechanism. This can be a little tricky as there are many different types of seat belts. Once the seat belt mechanism is disconnected, remove the seat frame.

With the rear seats removed, you can now clean out the trunk area of any clutter.

Finally, remove the black styrofoam cubby located right behind the seat backs.

Now you should have clear access to the fuel pump and can continue with the fuel pump replacement.

Disconnecting the battery and fuel lines

First, locate the battery in your Subaru Forester. It is usually located in the engine bay, often near the front of the vehicle. Once you have located it, identify the negative terminal, which is typically marked with a "-" symbol or a black cover. You may need to remove a protective plastic cover to access the terminal. Use a 10mm socket to loosen and remove the negative battery cable from the terminal. Set the cable aside, ensuring it does not touch any metal surfaces.

Now, let's move on to the fuel lines. The fuel lines are the hoses that carry fuel from the fuel tank to the engine. They are typically located near the fuel tank and can be identified by their flexible rubber or metal tubing. Before disconnecting the fuel lines, relieve the fuel system pressure to reduce the risk of fuel spraying out. To do this, turn the ignition key to the "On" position for a few seconds without starting the engine. You should hear the fuel pump running for 2-3 seconds. Then, turn the key back to the "Off" position.

Next, locate the fuel line quick-disconnect fittings or couplings. These are usually spring-loaded and can be released by pressing a tab or pulling back a ring. Place a rag or towel around the fittings to absorb any spilled fuel. Firmly press the tab or pull back the ring to release the fitting. You may need a pair of pliers to do this. Be prepared for a small amount of fuel to spill out, so have a container ready to catch it. Once the fitting is released, separate the fuel line from the fuel pump inlet or outlet.

Repeat this process for any additional fuel lines connected to the fuel pump. It is important to label or remember the orientation of the fuel lines to ensure proper reconnection during reassembly. Additionally, be cautious of the fuel pump's wiring harness, which provides power to the pump. It is typically located near the fuel lines and should be unplugged and set aside carefully.

By following these steps, you will have successfully disconnected the battery and fuel lines, allowing you to proceed with removing and replacing the fuel pump in your 1999 Subaru Forester. Remember to exercise caution when working with fuel and always work in a well-ventilated area to avoid inhaling fumes.

Replacing the pump and strainer bag

To replace the pump and strainer bag of your 1999 Subaru Forester, you will need the following equipment and tools:

• 8mm, 10mm, and 12mm sockets
• A short extension
• Phillips and flathead screwdrivers
• Needlenose pliers
• A respirator
• Replacement parts, including a new pump and strainer bag

• Remove the green plug on the bottom row of three, located under the steering wheel near the hood release.
• Start the car and let it run until it stops due to a lack of fuel.
• Disconnect the battery using a 10mm socket.
• Remove the gas cap.
• Clean out the trunk area and remove any clutter.
• Remove the seats, including the seat bottom and the passenger side section of the 60/40 split (using a 12mm socket).
• Remove the black styrofoam cubby located right behind the seat backs.
• Remove the four access screws using a Phillips head screwdriver.
• Disconnect the fuel lines and clips, being sure to remember how they were connected.
• Unbolt the eight nuts on the black access panel with an 8mm socket. Be careful not to lose any of the nuts.
• Carefully remove the entire assembly, taking care not to bend or break any components, such as the wire arm. You may need to tilt the assembly towards the LATCH anchor points and lift it out with a possible twist.
• This is the most important step: replace the old pump and strainer bag. Be extremely careful not to bend the wire coat hanger-looking thing, as it can affect your fuel gauge accuracy.
• Use a new rubber gasket or clean the existing one thoroughly. Also, clean the access panel surround. Consider using a sealant to create an airtight seal and prevent the CEL from coming on.
• Put everything back together, following the previous steps in reverse. Reconnect the fuel lines and quick clips, ensuring that all connections are secure. Reinstall the foam gasket and access panel.
• Reinstall the styrofoam cubby and the seats.
• Reconnect the green clip under the dashboard.
• Reconnect the battery.
• Tighten the gas cap.
• Start the car and hope it works!

Note: It is recommended to perform this task with an almost empty gas tank and to wear a respirator to avoid inhaling fumes. Additionally, take your time to vacuum and clean the area, and don't forget to collect any spare change you find!

Reassembling and testing

Once you have installed the new fuel pump, it is time to reassemble the various components and test your work. Here is a step-by-step guide to help you through the process:

Reassembling

• Reinstall the straps and bolts that hold the fuel pump assembly in place.
• Reconnect the filler fuel hose and the electrical connector to the new fuel pump.
• Reconnect the negative battery cable. Be careful not to overtighten any connections.
• Refill the gas tank and ensure it is properly secured.
• Reinstall the seats and any other components that were removed for access.
• Reconnect the green clip under the dashboard, near the hood release.

Testing

• Start the car and let it run for a few minutes. Listen for any unusual noises and check for any signs of fuel leaks.
• Take the car for a road test to verify that the new fuel pump is functioning correctly. Drive at different speeds and pay attention to how the engine is performing.
• If there are no issues, your fuel pump replacement is complete!

It is important to note that these steps are just a general guide, and there may be variations depending on your specific vehicle and the repair process. Always refer to a qualified mechanic or a repair manual for more detailed instructions.

Frequently asked questions