•

Ascent: 23.8 +/- 2.5 mm (.937 +/- .098 in.) measured
in 3 positions around the ring nut. The best tool for
doing this measurement is a digital caliper as shown
below. Measure from the top edge of the ring nut
“teeth” to the top surface of the tank.

•

Impreza: After the specified torque is reached,
measure the height using a digital caliper as shown
below between the flats adjacent to the ring nut
“teeth” to the top surface of the tank in 3 places. All 3
measurements must be between 1.5 mm of each other.

Pump Indexing
Arrow

ASCENT

IMPREZA

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Bulletin Number: WRD-20R Revised Date:08/27/21

Page 19 of 51

NOTE: In cases where the ring nut does not thread properly onto the fuel tank, it will be necessary
to “jump” one thread to avoid cross-threading of the ring nut and tank. To do this, begin threading
the ring nut onto the tank at a minimal angle until slight turning resistance is felt. The ring nut thread
starting points are identified by the triangle arrow ∆ on the Impreza ring and the set of 3 lines close
together on the Ascent ring nut (Green arrows in photo below and highlighted with black marker on
the parts). Once the resistance is felt, apply a quick, downward, non-percussive force to the side of
the ring opposite from where the threads were started. A slight “pop” sound should be heard. Once
the pop has been heard and while keeping downward pressure on the ring nut, continue threading the
ring nut onto the tank until it can no longer be turned by hand. Proceed with the remainder of the
tightening and height adjustment procedures as described above. See Appendix C starting on pg. 51
for more information and a video on this CRITICAL step.

ASCENT RING

IMPREZA RING

Other differences (between the Legacy / Outback procedure) to be aware of:
LEGACY / OUTBACK PUMP

1. The fuel pump is secured to the filter
assembly with 3 retaining claws instead of 5.
2. Instead of having 2 fuel line connections on
the pump assembly, Impreza and Ascent only
use 1.
3. Impreza does not utilize a “saddle” type fuel
tank therefore, there is also no jet pump.
IMPREZA / ASCENT PUMP

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Bulletin Number: WRD-20R Revised Date:08/27/21

Page 20 of 51

4. Both models utilize a large o-ring seal between the
fuel pump assembly and the tank instead of a rubber
gasket. Ascent uses an additional blue plastic sealing
washer between the lock ring and top of the fuel pump
assembly.
5. Ascent has a jet pump fuel line connection to the fuel
chamber inside the tank. When removing this line, if
desired, it can be secured either with tape or a piece of
Mechanic’s wire under the connector slider to keep it
from dropping inside the fuel tank.
END OF IMPREZA & ASCENT TIPS

FUEL PUMP REPLACEMENT for 2019MY IMPREZA Models:

IMPORTANT PRECAUTIONS:
•

Place “NO OPEN FLAMES” signs near the working area.

•

Be careful not to spill any fuel, especially when working inside the vehicle.

•

Catch any leaking fuel from the removed fuel tube(s) using a small drain pan or cloths.

•

If the fuel level in the tank is 2/3 full or more, drain the fuel to below 2/3 full before starting
this procedure to avoid spilling any fuel.

•

To prevent static electricity discharge / spark, always discharge any static electricity before
starting this procedure using an anti-static cord and / or touching a grounded metal part of the
vehicle body (e.g. door striker).

•

Insure there is plenty of ventilation by opening windows of the vehicle and the service area.

•

ALWAYS remove the fuel cap to release any accumulated evaporative / vapor pressure.

As mentioned earlier, select Fuel Filter REMOVAL in the applicable Service Manual to get the
complete, detailed procedure for separating the fuel pump / filter sock from the complete fuel pump
assembly. The following instructions will follow the Service Manual with additional photos to help
clarify the step where applicable.

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Page 21 of 51

For this Campaign procedure, the
connector cable (9) does not need
to be replaced.
However, if either of the following
conditions are found, replace it.
• Cracking of the harness insulation or
• Deformation / discoloration of any
connector or terminal.

1. Park the vehicle where the work will be performed. Release the fuel pressure:
•

Locate and remove the fuel pump fuse in the under-hood fuse box (M/B).

•

Start the engine and allow it to run until it stalls. NOTE: Even after the engine stalls, there
will still be a small amount of residual pressure left in the fuel system. Crank the engine
another 5 seconds with the starter.

2. Enter the driver seat and lower all windows. Using the fuel gauge in the Combination Meter,
check the fuel level.
•

If the fuel gauge shows two thirds (2/3) or more: go to STEP 3

•

If the fuel gauge shows less than two thirds: go to STEP 4.

(STEP 3:) The PREFERRED method for draining fuel will be to use the special adapter p.n.
42099FL030. CAREFULLY remove the rear seat cushion assembly and fuel pump access cover.
Apply a length of door edge guard, flexible tubing or electrical tape around the pump access
opening as protection from cuts / abrasions from any sharp edges. Release the quick disconnect
fitting at the fuel pump outlet pipe. While covering the fuel pipe with a clean shop cloth to
catch any residual pressurized fuel, slide the fuel delivery pipe off the fuel pump outlet. Insert
the plastic temporary plug supplied in the kit into the removed fuel delivery pipe. The one-time
use temporary plug is included in the replacement fuel pump parts kit. This plug is not required if
the fuel pump assembly is being replaced due to the very short disconnection time.

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Bulletin Number: WRD-20R Revised Date:08/27/21

Page 22 of 51

•

Connect a sufficient length of 5/16” rubber fuel hose to the male hose barb portion of the
adapter fitting. Always secure it with a small hose clamp to prevent leakage. Remove the
plastic plug from the adapter and connect the adapter / hose assembly to the male fuel
discharge tube of the fuel pump as shown below. Put the other end of the rubber fuel hose
securely into a safety container to collect the drained fuel. Once the drain hose assembly
is securely in place, connect the SSM4, turn the ignition ON and from the Active test item
menu, select Fuel Pump Control to operate the fuel pump. Drain the fuel tank down until the
fuel gauge reads at or below 2/3 full.

Remove
Plug and
Discard

3. Disconnect the ground terminal from battery and wait 60 seconds before proceeding.

4. If not already done in STEP 3, CAREFULLY remove the rear seat cushion assembly, set it aside
in a clean, safe place. While pushing the corners of the rear seat cushion from above, pull the
knobs of the retaining hooks forward. Lift up on the front of the cushion assembly to disengage
the rear hooks and remove it.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21

Page 23 of 51

REMINDER: ALWAYS remove the fuel tank filler cap to release any remaining vapor pressure.

CAUTION:
• The Airbag system satellite safing sensor is located under the front center of the rear seat cushion.
Be careful not to apply any strong impacts to the sensor when working with the rear seat cushion
removed.
5. Fuel Pump Assembly Removal:
•

CAREFULLY remove the fuel pump access cover while paying close attention to avoid
damaging the foam seal between the cover and vehicle body. Replace the seal if damaged
with p.n. 96077FL00A (rare case).

•

Apply a length of door edge guard, flexible tubing or electrical tape around the pump access
opening as protection from cuts / abrasions from any sharp edges.

•

Release the quick disconnect fitting at the fuel pump outlet pipe, and while covering the pipe
and connector with a clean shop cloth to catch any residual pressurized fuel, slide the fuel
delivery pipe off the fuel pump outlet tube. Insert the plastic temporary plug into the fuel
delivery pipe connector. The one-time use temporary plug is included in the replacement fuel
pump parts kit.

•

Disconnect the harness connector from the pump.

•

CAREFULLY using HAND TOOLS ONLY and the Ring
Nut Wrench tool shown here, remove the plastic retaining
ring securing the fuel pump assembly in the fuel tank.
NOTE: Make sure the removed fuel delivery pipe is ON
TOP of the tool as shown and not pinched under it.

Ring Nut
Wrench

Removed Pipe
on TOP of Tool

•

CAREFULLY remove the fuel pump assembly from the
fuel tank. Use a vacuum tool with a reservoir, squeeze bottle or an equivalent tool to remove
residual fuel from the fuel chamber of the pump assembly along with a small catch pan to
prevent spilling fuel as the pump assembly is removed. IMPORTANT: Do not let the fuel
level sensor arm or float contact the tank opening during removal.

•

Once the fuel pump assembly has been removed, install the applicable plastic plug tool into
the fuel tank opening to prevent contamination from entering the tank and fuel vapors from
accumulating in the vehicle interior. If the plug is not available, cover the opening with a
clean shop cloth. The plug is not required when replacing the complete fuel pump assembly
due to the very short time the tank will be open for that repair.

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Page 24 of 51

6. After disconnecting the pump and sending unit harness connectors from the underside of the top
flange, CAREFULLY remove the fuel sending unit from the pump chamber.
IMPORTANT: If any damage e.g. distorted or melting plastic connectors, overheated wiring or
terminals is identified, the harness MUST be replaced. Release the retaining clip (a plastic trim
tool is being used here) and slide the sending unit upward. NEVER touch the contact surface of
the sending unit and use care to avoid bending or otherwise damaging the float arm and contact
point.

7. CAREFULLY disconnect both the fuel pump and fuel sending unit harness connectors and
remove the wiring from the retaining clips. Note the wire routing prior to disassembly for
reference during reassembly.
•

Compress the spring (fuel filter assembly) and remove / discard the (one-time use) c-clip.

•

IMPORTANT: When releasing the retaining claws as described in the following steps,
move them only as far as needed to disengage them. If any
break, the affected component must be replaced.

•

Using a flat-blade screwdriver wrapped with protective tape (or
equivalent), release the connector for the fuel tube at the bottom of
the fuel chamber. Remove the fuel tube from the side of the fuel
chamber as shown.

•

CAREFULLY disengage three claws of the fuel pump holder
from the fuel chamber assembly. Remove the fuel pump and filter
assembly from the chamber.

Fuel Pump Holder

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Bulletin Number: WRD-20R Revised Date:08/27/21

Page 25 of 51

•

CAREFULLY remove the fuel pump holder from the fuel filter
assembly.

•

Disengage the 3 claws at the bottom of the fuel pump.

•

Using the flat tip screwdriver or similar tool wrapped with a
protective tape, press on the fuel pump and remove the fuel
pump from the fuel filter assembly.

IMPORTANT: Remove the
o-ring and spacer from
the original fuel pump.
The spacer is reused. Put
the removed pump in a
vise and crush it as shown
here to eliminate any
chance of it being reused.

•

Transfer the white plastic spacer (B) to the new pump and install the new o-ring (A) from the
kit to hold the spacer in place. Lubricate the new o-ring with gasoline.

•

IMPORTANT: Always confirm the original o-ring came out
of the filter assembly during disassembly. If not, use a rubbertipped or plastic (non-marring) pick tool to CAREFULLY
remove it without scratching the filter assembly bore. Transfer
the white plastic spacer (B) to the new pump and install the
new o-ring (A) from the kit to hold the spacer in place. It is
CRITICAL for the bushing and NEW o-ring to be installed
on the new pump in the proper order. Always lubricate the
new o-rings with gasoline.

Plastic
Non-Marring
Pick Tool

(C)
(A)
(B)

8. Install the new fuel pump into the fuel filter assembly. Using
the image here as a guide, lay the partially reassembled pump
assembly on the bench horizontally and insert the new pump
into the fuel filter assembly. Using both hands, CAREFULLY
press the new pump and filter assemblies together until a “click”
is heard from ALL of the new fuel pump’s retaining claws. If
the new pump does not fully seat and lock into position, make
sure the old o-ring (A) is not still in the bore as shown above.
See Appendix B starting on pg. 48 for more information and a
video on this CRITICAL step.
Bulletin Number: WRD-20R Revised Date:08/27/21

Continued...
Page 26 of 51

•
•

Refit the fuel pump holder to the fuel filter assembly.
Reinstall the fuel filter assembly into the fuel chamber. Make sure the fuel tube and the
spring are properly positioned as shown in the photo and illustration below.

•

Confirm the 3 claws securing the fuel filter assembly into the fuel
chamber are fully engaged.

•

Secure the fuel tube to the outside of the fuel chamber and
reconnect it at the bottom.

•

Push the fuel filter assembly in the direction of the arrow to
compress, and install the new clip supplied in the kit.

•

Leak test fuel pump assembly to confirm there is no leaks PRIOR TO installing the assembly
into the fuel tank. Using the Redline Smoke Pro, apply approximately 200Kpa (29 PSI) to
the pump assembly as shown. Confirm the applied pressure can be held for 10 seconds. If
the pressure can be held, continue with installation. If pressure cannot be held check the jet
pump seating and o-ring condition. If the pump does not pass the leak test and disassembly
is required, it is IMPORTANT to never reuse the one-time use o-ring.

9. CAREFULLY refit the fuel level sensor assembly to the fuel chamber. Put the (thinner) fuel
lever sensor wires into the 2 retaining clips first followed by the fuel pump wires IN THAT
ORDER.

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Bulletin Number: WRD-20R Revised Date:08/27/21

Page 27 of 51

•

CRITICAL: ALL surfaces of the new pump assembly o-ring, top gasket, underside of the
ring nut along with the surfaces described and shown below: fuel tank neck rim (A) pump
flange top and bottom faces (B) and (C) must be thoroughly wiped clean and completely dried
BEFORE re-installation. This will help prevent the pump from turning with the ring nut during
final tightening.

(A) Fuel Tank Rim

•

(B) Pump Flange Top Face

(C) Underside of Pump Flange

Use CAUTION to keep the fuel level sensor arm from contacting the fuel tank opening. If
the arm were to become bent, the fuel gauge may not read properly.

10. CAREFULLY reinstall the fuel pump assembly into
the tank in the proper position / orientation as shown
below. ALWAYS use the new gasket included in
the kit. Position the indexing arrow ∆ between the
molded-in hash marks (blue arrows) on the fuel tank.
•

Install the new ring nut included in the kit. The
new ring nut has a triangle index mark ∆ (shown
in black here for illustration purposes) similar to
the fuel pump to indicate the ring nut thread
starting point (if needed).

•

NOTE: In a case where there is
difficulty getting the ring nut threads
started onto the fuel tank threads,
align the starting points, install the
ring nut wrench then press down
firmly by hand on the ring nut
wrench to “jump” the ring nut thread
past the interference point. A “pop”
sound will occur, the ring nut should
now be parallel to the top of the fuel
tank and able to be tightened by
hand. See Appendix C starting on
pg. 51 for more information and a
video on this CRITICAL step.

Pump Indexing
Arrow

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Page 28 of 51

11. CAUTION: SLOWLY tighten the new ring nut to 130 Nm (96 ft.
lbs.) while paying close attention to make sure the fuel pump does not
rotate along with the ring nut. If the pump were to turn more than 45
degrees, the fuel level sensor will likely be damaged. When properly
tightened, the index mark on the ring nut ∆ should align with the fuel
pump indexing arrow ∆ (Center Line (A).
12. CRITICAL: Using a caliper with depth gauge, measure the dimension
in 3 positions between the top of the ring nut and the top of fuel tank
as shown in the illustration and photo (inset) below. The difference
between the three measurements cannot exceed ±1.5mm or .060 inch.

CAUTION:
•

If the difference between any of the three measurements exceeds ±1.5mm or .060 inch, loosen and
re-tighten the ring nut to correct any cross-threading.

•

If the ring nut or fuel pump gasket are deformed, cracked or damaged, they MUST be replaced.

13. Remove and discard the plastic temporary plug from the fuel delivery pipe and re-connect the
pipe to the fuel pump outlet tube. Make sure the connector is all the way onto the outlet tube then
lock the slider. Tug on the fuel delivery pipe to be sure it is fully locked in place.

IMPORTANT REMINDERS: Discard the plastic fuel line plug as it is a one-time use item.
Reusing the plug may damage the connector’s internal o-ring and cause a fuel leak.