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

If you're looking to replace the fuel pump in your Subaru Forester, you'll need to set aside a few hours and prepare to get your hands dirty. The fuel pump is located inside the fuel tank, and you'll need to drain the tank and remove it to access the pump. This job is moderately complicated and best performed by a professional mechanic or dealership service department. However, if you're feeling adventurous, here's a step-by-step guide to help you get started.

First, park your car on a level surface and set the parking brake. Locate the pump assembly in the fuel tank and have someone turn the key to the ON position. You should hear the fuel pump hum for 2-3 seconds. If it doesn't, you likely need to replace the pump. Next, find and verify the vehicle's fuel pump relay and fuse, replacing the fuse if necessary. Once you've checked the fuel pump's operation and confirmed that it's not working, you'll need to relieve the fuel system pressure and disconnect the negative battery cable. Drain as much fuel as possible from the tank, and disconnect the filler fuel hose and electrical connection to the old pump. Support the fuel tank using a jack stand and a block of wood, and remove the entire pump assembly. Remove the hose clamps, disconnect the fuel line or fuel tank hose, and extract the old pump. Compare the new fuel pump to the old one to ensure you have the correct part, then install the new pump by connecting all the fuel lines. Reinstall the straps and bolts, and reconnect the filler fuel and electrical connector, as well as the negative battery cable. Finally, fill up the gas tank and take your car for a test drive to ensure the new pump is working properly.

Removing the rear seat

To remove the rear seat of a Subaru Forester, follow these steps:

Firstly, disengage the middle seat belt by inserting the ignition key into the white slot on the seat belt clasp. Then, lift up the seat bottom to expose the clasp and pull the handle to release the front of the seat bottom. Now, pull the rear seat forward as much as possible, using gloves to reach behind the seat to feel the hook and loop holding the back of the seat in place. The hook will be attached to the floor and the loop to the seat foam.

Next, lift up on the seat bottom and push inward, pushing downward on the seat loop to disengage it from the hook. To reinstall the seat bottom, start by connecting the hook and loop, then line up the clasp and push down on the seat bottom to lock it in place.

If you are looking to remove the rear seat to access the fuel pump, you will need to remove the foam sections in the cargo area. There are three of these, not including the spare wheel cover, which simply lifts out. These are all held in place with one plastic pin. Once removed, you will see four Phillips head screws holding down the cover.

Disconnecting the electrical connectors

• Locate the Electrical Connectors: The electrical connectors for the fuel pump are usually located in the engine compartment or inside the fuel tank. Refer to your Subaru Forester's service manual or consult a trusted mechanic if you are unsure about the exact location.
• Prepare the Work Area: Before disconnecting any electrical connectors, it is important to take the necessary safety precautions. Park your car on a level surface and set the parking brake to ensure it doesn't move. Make sure the engine is cool before starting work and always wear protective gear, including gloves and eye protection. Place a rag or a container under the connectors to catch any fuel that may spill during the process.
• Disconnect the Negative Battery Cable: Before proceeding, it is crucial to disconnect the negative battery cable to prevent any accidental electrical shorts. Locate the negative terminal, which is usually marked with a "-" sign, and use a wrench or a suitable tool to loosen the nut or bolt holding the cable in place. Once it is loose, carefully disconnect the cable from the battery terminal.
• Identify the Connectors: There may be multiple electrical connectors associated with the fuel pump. Identify the correct connectors by referring to the service manual or seeking advice from a qualified mechanic. It is important to be certain before proceeding.
• Carefully Disconnect the Connectors: Using a suitable tool, such as a connector release tool or a small screwdriver, carefully pry or squeeze the locking tab or release mechanism on the connector. Do not force the connector, as this may damage the locking tab or the connector itself. Gently pull the connector apart, ensuring that you are pulling directly away from the connection to avoid bending or damaging the terminals.
• Secure the Connectors: Once the connectors are disconnected, it is important to secure them to prevent accidental reconnection or damage. You can use tape or zip ties to keep the connectors separated and organized. Place the connectors in a safe location away from the work area.
• Absorb any Spilled Fuel: If any fuel has spilled during the disconnection process, use an absorbent cloth or rag to wipe it up. Ensure that the area is clean and free of any fuel residue before proceeding with the fuel pump replacement.

Remember to work carefully and methodically when disconnecting electrical connectors. If you are unsure about any step, it is always best to consult a professional mechanic to ensure the job is done safely and correctly.

Draining the fuel tank

Park your Subaru Forester on a level surface and engage the parking brake. This ensures the vehicle remains stable during the draining process.

Locate the fuel pump assembly inside the fuel tank. This can be accessed through an access panel in the passenger compartment or by removing the fuel tank from the vehicle. If there is no access panel, you will need to drain the fuel tank before lowering it.

Before proceeding, relieve the fuel system pressure and disconnect the negative battery cable. This is an important safety measure to prevent any accidental ignition.

Now, proceed to drain the fuel tank. Place a suitable container under the fuel tank to collect the drained fuel. Be extremely cautious as gasoline is highly flammable. Use the correct tools and safety equipment, including gloves and eye protection.

Disconnect the filler fuel hose and the electrical connection to the old pump. This will allow you to access the pump assembly and begin the draining process.

Support the fuel tank using a jack stand and a block of wood. This will provide stability and prevent any accidental damage to the tank.

Remove the entire pump assembly, including the pump and the fuel level sending unit, and carefully lower the tank. You may need an assistant to help with this step.

Once the tank is lowered, you can proceed with removing the old pump and installing the new one. Follow the manufacturer's instructions or a reliable guide for the specific model of your Subaru Forester.

After installing the new fuel pump, reinstall the straps and bolts that secure the fuel tank. Reconnect the filler fuel hose and the electrical connector. Finally, reconnect the negative battery cable.

Fill the gas tank and conduct a road test to ensure the new pump is functioning correctly. Pay attention to any unusual noises or performance issues.

Remember, working with gasoline can be dangerous, so it is essential to take the necessary precautions and have the appropriate tools and safety equipment. If you are unsure about any part of the process, it is best to consult a professional mechanic.

Removing the fuel pump assembly

To remove the fuel pump assembly from your Subaru Forester, follow these steps:

Park your car on a level surface and engage the parking brake.

Locate the pump assembly in the fuel tank. Have an assistant turn the key to the "ON" position, and listen at the filler opening. A functioning fuel pump should be audible for 2-3 seconds.

Verify the location of the vehicle's fuel pump relay and fuse. If the fuse is damaged, replace it with a new one of the same amperage.

Check the fuel pump's operation. If the vehicle's fuel pump is working, the issue is resolved. If not, and the fuse and fuel pump relay are functioning, check for power and ground at the fuel pump. If there is power and ground, the pump is faulty and needs to be replaced.

Relieve the fuel system pressure and disconnect the negative battery cable.

Drain as much fuel as possible from the fuel tank. Disconnect the filler fuel hose and the electrical connection to the old pump.

Support the fuel tank using a jack stand and a block of wood. Remove the entire pump assembly, including the pump and the fuel level sending unit, and carefully lower the tank.

Remove all hose clamps, disconnect the fuel line or fuel tank hose, and extract the old pump from the gas tank.

To access the fuel pump assembly, you will first need to remove the rear seat or cargo area carpeting. There will be foam sections in the cargo area that can be removed by pulling out the plastic pins. Once these are removed, you will see a cover held in place by four Phillips head screws. Remove these screws and carefully lift the cover, as there are electrical connections and fuel lines attached to the pump assembly.

Disconnect all electrical connectors and fuel lines from the pump assembly. Be careful, as some fuel may leak from the lines. You may need to use pliers to squeeze and remove some of the more tightly secured clips. Once all connections are disconnected, carefully remove the pump assembly, being mindful of the fragile fuel level gauge attached to it.

At this point, you can proceed with installing a new fuel pump assembly, following the above steps in reverse order.

Installing the new fuel pump

Now that you have removed the old fuel pump, it is time to install the new one.

First, compare the new fuel pump to the old one to ensure that you have the correct part. Once you have verified that you have the right pump, connect all the fuel lines to the new pump. Make sure that all the hoses are properly secured with hose clamps.

Next, reinstall the straps and bolts that were removed earlier. Reconnect the filler fuel hose and the electrical connector. Finally, reconnect the negative battery cable.

Now, fill up the gas tank and start the engine to test the new pump. Verify that the pump is functioning correctly and that there are no leaks. Take the car for a road test to ensure that the new pump is working as expected.

Note: It is recommended to replace the fuel filter when installing a new fuel pump to avoid any issues with the fuel system.

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