How do you change the fuel pump in a 1991 Subaru Legacy?

Answer 1

This answer is for a fuel-injected non-turbo model. I guess it will probably apply to most other models, too. In fact many other makes and models of cars follow the same pattern of work as outlined here. 1. First of all you have to release the fuel pressure in the lines by doing the following. 1a. The fuel tank is under the rear seats of the car and there is an access lid in the bodywork which you need to locate and remove. This somewhere about under the base of the rear seat back and is fastened down with four bolts. 1b. Disconnect the multi-way connector which feeds the unit in the top of the tank. This unit is the combined fuel pump and guage sender unit which you will be removing further on. 1c. Start the engine and run it until it stalls. 1d. Crank it over 5 more revolutions and make sure you switch off the ignition and remove the key. (you don't want any accidental sparks, do you?) 2. Now you will remove the pump as follows. 2a. Label the three pipes and draw yourself a diagram (or take a digital photo) so that you know which pipe goes where. 2b. Disconnect the pipes by undoing the clips. These vary in design and are often tricky to remove on an older car. The screw type often benefit from a little penetrating oil applied but remember to wipe all surplus off the rubber tubes after since oil can be bad news for some types of rubber in the long term. 2c. Clean all round the unit and immediate surroundings to try to ensure that no dirt will fall into the fuel tank when you remove the unit. 2d. Now undo the eight nuts securing the unit. 2e. Now the tricky bit. Between the flange of the unit and the tank is a fuel-tight gasket. Unless you already have a new one to hand, you need to preserve the old one intact as you carefully loosen the unit from the tank. Assembly is exactly the reverse procedure. When you come to start the engine, just wait a moment after switching on the ignition before starting. This will allow the pump to re-pressurise the fuel lines. This answer was written by a UK author so I apologise if some terms I have used are different in the US.