Subaru Fuel Pump In-Tank Leak
Posted to Technical Discussion Forum on 3/29/2014
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Had a 2003 Outback 3.0 brought to my shop with a no start.
condition. Fuel pump cycled on when ignition was turned on
but no fuel pressure. Checked Identifix at this point. Lots
if posts pointing to a metal cap on the fuel pump assembly
that cracks and causes a massive fuel leak within the tank.
Pulled the fuel pump assembly and, sure enough, that was the
problem.
It seems that this pump module has a reservoir within which
a filter can be installed. The aforementioned metal cap and
and an o-ring seals this reservoir. There are three tangs on
this cap that hold it on the reservoir. One tang has a male
spade connector for a ground wire and this is usually the
tang that develops a stress crack which allows the cap to
move down beyond it's sealing o-ring and dump all the fuel
pressure.
Subaru does not sell this cap separately- you gotta buy the
whole fuel pump module to the tune of $400 bucks. OUCH!!!
Four hundred clams for a 50 cent stamped piece of metal.
I'll cut to the chase here: starting in 2004 Subaru started
putting a filter in this reservoir. Google or EBay this part
number: W0133-1617990. This filter includes the metal cap
you need. This filter and cap is around 60 bucks.
A couple of tips: use a large pair of Channellock pliers to
r&r the cap. Before you install the cap lube the o-ring.
There is talk on the Subaru forums about the stress crack
being caused by the cap' so- ring swelling. I'll post again
here when I find a source for the o-ring. The o-ring is not
included with the filter/cap.
Thomas Brandolini Owner/Technician Haverhill Tune-Up East Kingston, New Hampshire, USA
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