Fuel tank & piping diagrams here

[SVXdc]

I dug up some pics and links for the fuel tank and fuel system diagrams, out of curiosity and to post a reply in an unrelated thread, and figured these would be useful in their own thread.

If you think the tank looks remarkably similar to the rear seat, that's because it lies in the space below that seat and the front edge of the trunk.

Fuel tank drawings, courtesy of SubaruParts.com:

Part numbers/names:

42004B    $0.75  Clip-fuel hose
42010   $436.64  Tank complete-fuel
42017    $56.72  Band assembly-fuel tank,center
42021   $272.82  Pump assembly-fuel
42025D   $16.62  Packing-tank
42031   $130.68  Filler cap assembly   no.1
         $38.74  Filler cap assembly   no.2
42037     $5.26  Clamp-bracket pump
42037C    $3.24  Clamp-hose   no.1
          $4.94  Clamp-hose   no.3
          $1.42  Clamp-hose   no.2
42052J    $4.41  Bracket-roll over valve
42052P   $25.23  Bracket-sab assembly
42052T  $126.49  Bracket-main unit assembly
42054D  $109.03  Cover-tank exhaust,a 4wd
42057D    $1.84  Plate clamp
42058     $0.58  Flange bolt
42062A   $14.10  Pipe-delivery
42062B   $14.10  Pipe-return
42062C   $14.10  Pipe-evaporator
42075     $8.01  Hose-evaporator
42075A    $9.19  Hose-return
42075O   $30.52  Hose-fuel
42084C   $32.63  Valve-roll over
42084D   $31.75  Valve-breather
81803    $18.17  Cord-fuel   no.1
         $38.11  Cord-fuel   no.2
F96001    $7.94  Hose clamp
M000065   $0.47  Flange bolt
W18601    $1.04  Clip

Fuel piping drawings:

Part numbers/names:

42004C    $3.85  Clip-harness
42025     $5.93  Packing-filler pipe
42031    $15.20  Filler cap assembly
42032     $1.73  Ring assembly-filler
42035    $89.78  Canister
42037B    $3.85  Clamp-pipe   no.1
          $2.11  Clamp-pipe   no.4
          $2.32  Clamp-pipe   no.2
          $2.32  Clamp-pipe   no.3
42037C    $3.96  Clamp-hose   no.7
          $0.58  Clamp-hose   no.3
         $15.02  Clamp-hose   no.5
          $4.94  Clamp-hose   no.2
          $2.32  Clamp-hose   no.1
          $2.32  Clamp-hose   no.6
          $1.42  Clamp-hose   no.4
42041     $6.87  Band assembly
42043A   $10.06  Cushion-fuel tank drain
42045     $7.59  Protector-pipe air ventilator
42051B    $8.09  Grommet-fuel pipe,rear
42051C    $5.03  Grommet-front pipe assembly
42051D    $4.88  Grommet-ventilator pipe a
42051E    $5.03  Grommet-ventilator pipe b
42052    $15.28  Bracket complete-fuel filter
42052C   $16.92  Bracket complete-canister
42052E    $2.25  Bracket-pipe fuel
42062    $21.74  Pipe-air ventilator
42062A   $49.34  Pipe-delivery
42062B   $49.34  Pipe-return
42062C   $47.90  Pipe-evaporator
42064D    $4.86  Pipe-drain
42065    $80.59  Filler pipe complete
42072    $21.22  Filter-fuel tank
42074     $3.73  Tube-spiral
42075E    $6.92  Hose-pump / pipe
42075H    $4.28  Hose-canister
42075Q    $3.67  Hose-pipe / pipe
42084    $12.09  Valve-filler
42084A   $27.90  Valve,2 way

Underneath the carpet in the trunk, just behind the rear seat back, is an access panel. The top of the fuel tank is just below that panel. The tank extends from there down and forward underneath the rear seats, straddling the exhaust and driveshaft.

Access panel (photo by Mike621, click for larger image):

Location of power harness for fuel pump (picture in post #3): fuel filter question

Fuel system diagram from service manual: Fuel system diagram needed (post #8)

Picture of evaporation charcoal cannister: Smells like gas w/ acceleration? (post #11)

[SVXdc]

(placeholder for future pics/info)

[scottsubarus]

Yea, it's not a fun job to R&R the tank. Had to have my son do it twice when I had a fuel tank leak due to a hole.

Glad I could just pay him in beer!

[Blacky]

Yes, I had mine done also for rusted out fuel lines. You have to remove the whole back end including the subframe. It was an 8 hour job but my mechanic only charges $35.00/hr so around $250.00.

[Green1995SVX]

Originally Posted by Blacky

Yes, I had mine done also for rusted out fuel lines. You have to remove the whole back end including the subframe. It was an 8 hour job but my mechanic only charges $35.00/hr so around $250.00.

You can replace the rusty fuel lines with rubber fuel hose and just slide the hose down the outside between the tank and the car body. No need to drop the tank.

[scottsubarus]

On mine, It would leak fuel bad until 1/2 tank and it would stop. Couldn't figure it out, so son took tank down as a last reasort and bingo...the culpret a piece of gravel about an 1 inch big had gotten thrown up and lodged between the plastic tank and the underbody of the car and rubbed a hole in it. Not wanting to spend the big money for a new fuel tank my son took some "cast flash" plastic from the edges of the fuel tank and made shavings out of them, used a heat pencil and melted a patch onto the hole, then spray sealed it. That repair lasted almost 2yrs, then started to leak again. This time though I could spend the time to find a used gas tank and was able to find one for $50 and had him install that. Never fun to do once, let alone twice! Again, it just cost me a couple cases of beer.

Always nice to have a Subaru tech in the family if you can't do things on your own.

Scott