Fuel System - Fuel Line Removal

SOURCE: Subaru Tech Tips

TITLE: Fuel Line Removal

APPLIES TO: 04 Legacy
04 Outback

SERVICE TIP:






The purpose of this article is to provide information regarding an important change to the fuel lines that are located in the engine compartment on all 2004MY and later Legacy/Outback H6 vehicles and normally aspirated H4 vehicles.

The engine compartment fuel line hoses now use a green 'quick connector' instead of the previous 'hose-clamp' style. When a 'quick disconnect' hose is removed properly, the hose can be reused without replacing the green retainers.

Although the service manual calls for the use of SST 42099AE000, OTC tool # 7660 can be used. OTC 7660 has two fitting sizes (3/8" and 5/16"). The Subaru fuel lines are 5/16" (the smaller of the two sizes). To properly remove the quick disconnect fuel lines:
- First relieve the fuel pressure from the fuel lines.
- After the fuel pressure is relieved, position the tool around the metal fuel line and close the handle.
- Next, push the tool into the retainer and gently pull the fuel hose away from the metal fuel line.

Reinstallation is accomplished by pushing the rubber fuel hose over the metal fuel line until it is properly seated. You should hear an audible 'click' when the fuel line properly seats into place. Be sure to verify your repair by starting the vehicle and checking for leaks.

NOTE: Should the green plastic retainers become damaged during this process, it will be necessary to replace the entire hose. The retainers are not available separately.