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Home >> Subaru >> 2021 >> Crosstrek Hybrid >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Injection System (HEV) >> Fuel Tank >> Removal

Fuel Tank: Removal

WARNING:
  • Place "NO OPEN FLAMES" signs near the working area.
  • The hybrid system includes a high voltage circuit. Mishandling could cause accidents such as electric shock or leak. Always check "WARNING (HYBRID SYSTEM)" and perform the proper operation. Ref. to PRECAUTION/WARNING>WARNING (HYBRID SYSTEM) .
CAUTION:
  • Be careful not to spill fuel.
  • Catch the fuel from the tubes using a container or cloth.
  1. Release the fuel pressure. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL>PROCEDURE>RELEASING OF FUEL PRESSURE .
  2. Drain fuel. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL>PROCEDURE>DRAINING FUEL (WITH SUBARU SELECT MONITOR) .
  3. Disconnect the ground terminal from battery. Ref. to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .
  4. Remove the service disconnect plug. Ref. to HYBRID ELECTRIC VEHICLE>SERVICE PLUG>REMOVAL .
    WARNING: After removal of the service disconnect plug, the condenser inside the inverter still has been charged to a high voltage. Wait for at least 10 minutes before handling the high voltage components, wiring, terminals or connectors.
  5. Remove the rear seat cushion. Ref. to SEATS>REAR SEAT>REMOVAL .
  6. Remove the service hole cover of fuel pump.
    G13230971Courtesy of SUBARU OF AMERICA, INC.
  7. Disconnect the connector from fuel pump.
    G13230972Courtesy of SUBARU OF AMERICA, INC.
  8. Lift up the vehicle.
  9. Remove the fuel tank protector and the cover of inverter with converter assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL TANK PROTECTOR>REMOVAL .
  10. Remove the floor under protector. Ref. to EXTERIOR/INTERIOR TRIM>FLOOR UNDER PROTECTOR>REMOVAL .
  11. Remove the rear exhaust pipe and muffler as a single unit.

    Rear exhaust pipe: 

    Ref. to EXHAUST (H4DO (EXCEPT FOR HEV))>REAR EXHAUST PIPE>REMOVAL .

    Muffler: 

    Ref. to EXHAUST (H4DO (EXCEPT FOR HEV))>MUFFLER>REMOVAL .

  12. Remove the tunnel stay.
    G13230973Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the rear differential. Ref. to DIFFERENTIALS>REAR DIFFERENTIAL (VA-TYPE)> REMOVAL .
  14. Remove the fuel filler hose (A).
  15. Disconnect the circulate tube (B) from the fuel tank. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE F) .
  16. Disconnect the vent tube (C) from the electric vent solenoid valve assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE H) .
    G13230974Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the bolt and clip (A) securing the inverter center water pipe and the resolver sensor harness.
    G13230975Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the bolt and nut securing the HV air conditioning wire (A) and power cable assembly (B).
    WARNING: Be sure to wear insulated gloves.
    G13230976Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the connector (A) and remove the support - sub frame (B).
    G13230977Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the connector (A) and remove the bracket securing the harness.
    G13230978Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the hose - air breather. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE E) .
    G13230979Courtesy of SUBARU OF AMERICA, INC.
  22. Disconnect the ground cable.
    WARNING: Be sure to wear insulated gloves.
    G13230980Courtesy of SUBARU OF AMERICA, INC.
  23. Support the inverter with converter assembly with the transmission jack and remove the bolt from the inverter with converter assembly.
    WARNING: Be sure to wear insulated gloves.
    G13230981Courtesy of SUBARU OF AMERICA, INC.
  24. Lower the inverter with converter assembly to the position that the work is possible.
    WARNING: Be sure to wear insulated gloves.
    CAUTION:
    • A helper is required to perform this work.
    • Be careful not to apply a load to the harness and pipe, etc. connected to the inverter with converter assembly.
  25. Disconnect the fuel delivery tube from the fuel pipe assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE A) .
    G13230982Courtesy of SUBARU OF AMERICA, INC.
  26. Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and remove the fuel tank from the vehicle.
    CAUTION:
    • A helper is required to perform this work.
    • Fuel may remain in the fuel tank. This will cause the left and right sides to be unbalanced. Be careful not to drop it.
    G13230983Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the protector and insulator from the fuel tank.
NOTE: Remove if necessary.
  1. Remove the clip (A) and remove the protector (B).
    G13230984Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the upper insulator (B) from the insulator holder (A).
  3. Remove the lower insulator (C) from the fuel tank.
    G13230985Courtesy of SUBARU OF AMERICA, INC.
  4. Remove the insulator holder (A) from the lower insulator (C).
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