lifting the seat. IMPORTANT NOTE: the side impact sensor is under the carpeting of the center
seating area. Avoid hard impacts to this area during seat removal and installation.
REMINDER: Always protect the surrounding trim and painted surfaces when removing and
reinstalling the seat assembly. Using a helper for this step is also STRONGLY recommended. Set
seat aside in a clean, safe place.
•

Remove the section of floor mat covering the fuel pump access cover. 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). With
the access cover removed, 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 one-time use plastic temporary plug into the
removed fuel delivery pipe. The plug is included in the replacement fuel pump parts kit.

5. Fuel Pump Assembly Removal:
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 42 of 72

•

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 nut securing the fuel pump assembly into the fuel tank.
NOTE: Make sure the removed fuel delivery pipe is ON TOP of the tool as shown and not
pinched under it.

•

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.

•

IMPORTANT NOTE: Ascent has a jet pump fuel
tube connection to the fuel chamber inside the fuel 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.

•

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.

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.

Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 43 of 72

•

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 screwdriver wrapped with protective tape (or equivalent), release the retaining claw

•

for the tube at the bottom of the fuel chamber then disengage the
fuel tube from the outside of the outside of the chamber.

•

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

•

Using a screwdriver wrapped with protective tape (or equivalent),
remove the tube assembly from the fuel chamber assembly, and
separate the fuel filter assembly and fuel chamber assembly as
shown below.

•

After separating the fuel filter from the fuel chamber assembly,

Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 44 of 72

inspect the fuel chamber to confirm the o-ring is not still in the
bore as shown here. If the o-ring remains, use a rubber -tipped
or plastic (non-marring) pick tool to CAREFULLY remove it
without scratching the fuel
chamber bore.

•

Remove the fuel pump holder then
disengage the 3 claws securing the fuel
pump to the filter assembly.

•

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

•

IMPORTANT: Confirm the o-ring is not stuck in the fuel filter
bore after removing the fuel pump. If needed, use a rubber-tipped
or plastic (non-marring) pick tool to CAREFULLY remove it
without scratching the filter assembly bore.

Plastic
Non-Marring
Pick Tool

•

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. 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.

Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 45 of 72

7. 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 A
starting on pg. 57 for more information and a
video on this CRITICAL step.

8. Leak test the fuel pump assembly to confirm there is no
leaks PRIOR TO reinstalling the assembly into the fuel
tank. Using the Redline Smoke Pro, apply approximately
0.47PSI (3.2Kpa) 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.

Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 46 of 72

9. Install the fuel filter assembly to the fuel chamber assembly. Position tube (A) and spring (B) for
the fuel filter assembly as shown in the figure.
•

Confirm the fuel tube routing and make sure all the claws securing the fuel chamber to the
fuel filter assembly are fully engaged as shown in the photos shown below.

NOTE: In the images below, a section of the fuel chamber has been cut away to make the fuel pipe
routing visible for reference. Normally, these fuel pipes are inside the chamber and not visible except
at the top.

ALWAYS inspect closely for any seepage or leaks around ALL fuel delivery tube
connections removed as part of this repair (including those under the hood if fuel
was drained) and around the ring nut.

Retaining Claw

•

Bulletin Number: WRG-21R;

IMPORTANT: Confirm this fuel hose runs
UNDER
retaining claw when installing
Revised:the
11/10/21
the pump / filter assembly back into the
fuel chamber as shown here.

Secure the fuel tube to the outside of the fuel

Continued...
Page 47 of 72

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.

10. 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.

11. 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.

12. CAREFULLY reinstall the fuel pump assembly into the tank using the new gasket included in
the kit.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 48 of 72

•

CRITICAL: DO NOT OVERLOOK RECONNECTING THE JET PUMP FUEL TUBE AT
THE BOTTOM OF THE FUEL CHAMBER.

•

After connecting the jet pump fuel tube, CAREFULLY lower the fuel pump assembly into
the tank and in the orientation shown in the photo below.

Pump Indexing
Arrow

IMPORTANT: This photo shows
the NEW ring nut and (Blue) seal
plate included in the kit already in
place. The ASCENT ring nut thread
starting point is identified by the
3 “teeth” close together (RED circled). Align the center (Green) tooth
(position mark) with the triangle ∆
mark between the
molded-in hash marks on the tank
(Blue arrows).

•

IMPORTANT: ALWAYS use the new gasket and blue ring nut seal plate included in the kit.
The photo above shows the thread STARTING POINTS for the ring plate and fuel tank. There
is a second set of molded-in hash marks 90 degrees CLOCKWISE from the starting point
hash marks which are the FINISHING POINT (End Range) hash marks shown as (c) in the
illustration below. See Appendix B starting on pg. 60 for more information and a video on
this CRITICAL step.

•

IMPORTANT: Before tightening the ring nut:
○ Make sure the fuel delivery tube is ON TOP of the tool and not pinched under it
○ Make sure the tool fits down fully and squarely onto the ring nut.
Continued...

Bulletin Number: WRG-21R; Revised: 11/10/21

Page 49 of 72

•

Using the ring nut tool, and the illustrations below as a guide, SLOWLY tighten the ring
nut ONE FULL TURN then continue until (b) is within the range of the End Range hash
marks (c). NOTE: (b) MUST be within the End Range hash marks for the ring nut to be fully
tightened.

•

CRITICAL: While tightening the ring nut, make sure the fuel pump does not rotate with the
ring nut otherwise, the fuel level sensor and the jet pump fuel tube may become damaged.
Always keep the Pump Indexing Arrow; (e) below and the fuel tank ring nut start mark (a)
below aligned.

STARTING POINT MARKS

END RANGE MARKS
Front of Vehicle

Front of Vehicle

LEGEND FOR THE ABOVE ILLUSTRATIONS:
(a) Ring nut installation position start mark (on fuel tank)
(b) Position mark (on ring nut)
(c) Ring nut installation position end range hash marks (on fuel tank)
(d) Fuel pump installation position range hash marks (on fuel tank)
(e) Position (Index) mark (for fuel pump)
(f) Toward FRONT of vehicle
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 50 of 72

•

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 wil
occur, the ring nut should now be parallel to the top of the fuel tank and able to be tightened
normally.

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 below. Confirm the measured
values of dimensions (D) are 23.8 ± 2.5 mm (0.937±0.098 in.).
LEGEND:
(A) Caliper with depth gauge
(B) Ring nut
(C) Fuel tank
(D) Dimension of ring nut and
(E) top of fuel tank
(F) Measuring point
(G) Toward FRONT of vehicle
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.

•

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 removed temporary 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.
•

Ensure both the pipe and tube are clean and dry
Continued...

Bulletin Number: WRG-21R; Revised: 11/10/21

Page 51 of 72

•

If the slider does not move easily, confirm the pipe is engaged on the tube

•

ALWAYS confirm the pipe is fully engaged after connecting and check for any leaks

13. Reconnect the harness connector to the fuel pump.
14. Reconnect the ground cable and harness connector to the battery sensor. While supporting the
sensor with one hand, torque the 12mm ground cable nut to 7.5 Nm (5.5 ft. lbs.).
15. Turn on the ignition switch to run the fuel pump. The engine does not need to be started. Check
closely for any leaks around ALL fuel delivery tube connections removed as part of this repair
(including those under the hood if fuel was drained) and around the ring nut.
16. Reinstall the inspection cover.
17. Reinstall the r/rear second row seat and trim in reverse order of removal. Torque the retaining
bolts to 53 Nm (39 ft. lbs.) Make sure the seat belt buckles are properly positioned.
18. Perform Fuel Tank Leak Test: See APPENDIX C on pg. 62 for the procedure.
19. Return any removed fuel back to the vehicle.
20. Deodorize the vehicle interior as necessary.
END OF ASCENT, 20MY LEGACY / OUTBACK SERVICE PROCEDURE

FUEL PUMP REPLACEMENT TIPS FOR 2018-19MY BRZ
The procedure for replacing the fuel pump on BRZ is very similar to other models. The major
differences are described here:
•

The BRZ uses a resin type tank. The fuel pump assembly is secured with a threaded locking
ring (ring nut) similar to Impreza and Ascent instead of a top plate secured by the studs
and nuts used on Legacy and Outback. The special tool required for the BRZ ring nut is
42099CA000. A ½-inch drive breaker bar and torque wrench are to be use in conjunction with
the special ring nut wrench. All one-time use parts are provided in the BRZ parts kit.

FUEL PUMP ASSEMBLY COMPONENT BREAKDOWN

Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 52 of 72

BRZ REAR SEAT MOUNTING POINTS

RING NUT WRENCH

42099CA000
•

NOTE: The fuel access cover on the BRZ is sealed differently than other models. The
BRZ uses butyl tape instead of a foam gasket. This will require the use of a protective sheet
supplied in the fuel pump kit for BRZ.

Removal of the Fuel Pump
•

Using a plastic trim tool CAREFULLY, remove the cover without bending or damaging the
sealing surfaces. Separate the harness from the cover and store the cover outside the vehicle.
This will help prevent the spread of butyl tape within the interior. When reinstalling the cover
and additional butyl tape is required, 3M TM Windo-Weld TM Ribbon Sealer #08610 can be
used.

Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 53 of 72

Butyl Tape

42099CA02

Door Edge Guard

•

Installation of the protective door edge guard around the service hole along with the supplied
protective sheet (42099CA020) is required to prevent the spread of butyl
tape.

•

Remove the ring nut with hand tools along with special
tool # 42099CA000.

Replacement of the Fuel Pump
•

Special attention is required regarding the jet pump o-ring. The o-ring is a one-time use part
and is supplied within the BRZ parts kit. Remove the o-ring from the fuel chamber using
a rubber-tipped or plastic (non-marring) pick tool to CAREFULLY remove it without
scratching the bore. A small amount of engine oil can be use when installing the new o-ring
onto the jet pump. Always confirm the o-ring is correctly seated.

•

Confirm the fuel pump harness is routed correctly. Install the thinner fuel lever sensor wires
into the two retaining clips before installing the larger pump wiring.

Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 54 of 72

•

Leak test the fuel pump assembly to confirm there are no leaks PRIOR TO reinstalling the
assembly into the fuel tank. Using the Redline Smoke Pro, apply approximately 0.47PSI
(3.2Kpa) 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.

Installing the Fuel Pump Assembly
Bulletin Number: WRG-21R; Revised: 11/10/21

Continued...
Page 55 of 72

•

A different type gasket is used for BRZ.

•

Clean the gasket contact surfaces. Then install the gasket and fuel pump assembly as shown
below.

Ring Nut Marking:
•

Match the center index marking of the fuel tank with the fuel pump
assembly as shown below.

•

Install the new plate (sealing) ring on top of the pump assembly followed by the ring nut.

Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 56 of 72

•

Align the markings as shown (in yellow) below to ensure the proper thread starting point for
the ring nut. Turn the ring nut approximately one full rotation by hand. Take special care to
not allow the pump assembly to turn while tightening the ring nut.

•

Using special tool #42099CA000, torque the ring nut to 85Nm (62.7 ft-lbs.).

Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21

Page 57 of 72

Height Adjustment Checks:
•