>

he fuel injection systems on present-day and mix with the gasoline. Even the transport

T vehicles have become so highly sophisticated

that we sometimes tend to overlook the
simple things. When a customer arrives at
the shop with a hard-start, no-start or stalling
problem, the natural tendency is to grab the scan
trucks were not very carefully inspected. So, it was
generally recommended that fuel filters be replaced
every 10,000 miles.

tool and look for a diagnostic trouble code, then

delve deeper into OBD II. Next, the focus generally
turns to the ignition system or the fuel injectors.
We often forget the simple things, like the fuel
filter. Granted, contaminated fuel isn’t as common
as it once was, but it can – and does – get into the
tank from time to time, which will eventually clog
that all-important filter.
Twenty-five years ago, fuel filter replacement
was always part of the routine maintenance job
then quaintly known as a “tune-up.” The filters were
typically located in the fuel line near the carburetor,
and were easy to get to and change. If this wasn’t
done on a regular basis, you might have a customer
come in complaining that the car would start
bucking, run out of power on the highway, and
stall, but then restart. These symptoms were the
tip-off that the filter was too restricted to allow
sufficient flow to keep the bowl filled. That
happened a lot because fuel-handling conditions What’s getting in there, anyway? Gasoline is usually cleaner
were not the best. Old, corroded in-ground tanks today than it used to be, but it’s never perfect, and sometimes it’s
allowed water and other contaminants to seep in badly contaminated.

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 Today, gasoline is kept much cleaner from the refining plant
to the storage depot, and from the transport trucks to the
service station tanks. Industry and government vigilance and
routine inspection has now provided consumers with the
cleanest fuel ever.Thus, we tend to forget that every so often,
fuel can become contaminated. Even a little water, rust,
sludge or dirt can cause big problems for the precision
injectors.Whether the contamination has built up over a long
period of time, or is due to one fill of tainted fuel, the results
are the same: possible driveability complaints, and damage to
the fuel injection system (perhaps even the engine, too) that
ranges from clogged injectors to a prematurely burned-out
fuel pump. That exhibits another big difference between the
old days and modern times: Mechanical fuel pumps were
robust, so clogging that caused the symptoms mentioned had
no effect on them. Besides, they were less expensive and easy A clogged filter increases the amperage
to replace. That situation is profoundly different today with
electric pumps. load on the pump, resulting in a rough commutator
and bouncing brushes.That, in turn, leads to broken
brush leads and failure.
Check the Fuel Pressure

On Subaru vehicles, it’s easy to check the fuel pressure
before and after the underhood filter. Most models specify
a fuel pump output flow pressure of 43.5 psi (an exception
is the 1992-1997 SVX, for which the spec is 36.3 psi).
Pressures lower than specified before the filter means
there’s a problem with the pump, tank pick-up or fuel
supply lines. A pressure drop at the output end of the filter
indicates a restricted filter. Remember; if you have a
clogged filter, there is a good chance that you have a
problem in the fuel tank, too, in the form of either an
accumulation of rust or dirt, a contaminated pick-up sock,
or both.

Februar y 2007 • Number 37 | 15

Subaru Fuel FIlters
One of the most overlooked troubleshooting steps is
checking fuel pressure, which is easy to do.
If you’re working on models old enough
to have throttle-body injection, you
should not only have a regular fuel
pressure gauge, but also a low-
reading version to help reveal
problems at smaller psi readings.
Be sure to refer to the correct Subaru Service Manual for
the model you are servicing for the correct filter, pump
output flow pressure and tightening specifications.
The canister-type fuel filter found on most Subaru models
is conveniently located for inspection or replacement.
16 | The End Wrench > w w w. e n d w r e n c h . c o m
Subaru Fuel Filters
You’ll find three basic types of fuel filters on Subaru
vehicles. Models prior to 2004 had only the underhood
canister-style fuel filter to supplement the mesh pickup
screen on the fuel pump pick-up.
The 2004 and later WRX and STI models use an
underhood filter and an additional filter built into the in-tank
fuel pump, as do 2005 and later turbo models.
Non-turbo vehicles use a cartridge-type fiber filter
incorporated into the fuel pump assembly.
All 2.5-liter DOHC turbocharged vehicles: 2005-2007
Forester XT, 2004-2007 STi and 2006-2007 WRX use a
special high-flow filter assembly that fits into the in-tank
pump structure.
Starting in 2006, all Subaru models were equipped with an
in-tank filter.
The underhood canister-type filter should
be replaced every 30,000 miles.
This cartridge-type fiber in-tank filter is found
on 2004 and later non-turbocharged models.
A high-flow in-tank fuel filter
is used on turbocharged models.
Troubleshooting Fuel System Problems
Subaru offers the helpful fuel system troubleshooting
chart on page 17 to diagnose and correct any fuel
system problems.
Be Preventive
A five-year study of component replacement rates on
vehicles in the United States by Industrial Marketing
Research (IMR) shows a steady 19% annual average for
replacement of fuel filters. Based on a conservative average
of 12,000 miles driven per year, this means that vehicle
owners are replacing the fuel filters on their vehicles about
every 60,000 miles — or double what most vehicle
manufacturers recommend for in-line fuel filters.
 Be sure to follow the recommended
fuel filter replacement intervals listed
in the Owners Manual of the specific
vehicle you are servicing. The old
cliché: “It’s better to be safe than
sorry,” certainly applies here.
Subaru recommends replacement of
the underhood canister-type filter
every 30,000 miles.You can prove this
to your customers by showing them
the Owners Manual, or by logging
onto the Subaru Technical Information
System (STIS) website while they look
over your shoulder.
For optimum results, always use
Genuine Subaru Parts available from
your local N.E.W. Horizons Dealer, and
always check the Subaru Technical
Information System (STIS) website
at http://techinfo.subaru.com for the
correct information and specifications
for the Subaru model you are servicing.
Service Note:When servicing the underhood
canister-type fuel filter,please note that 2002
and prior torque specifications call for
tightening the hose clamps to 1.0 Nm (0.7 ft.
lb.).When servicing 2003 and later models,
the specs call for 1.25 Nm (0.9 ft. lb.). ■
Troubleshooting Fuel System Problems
Trouble and Possible Cause Corrective Action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
• Defective terminal contact. Inspect connections, especially ground,
and tighten securely.
• Trouble in electromagnetic or electronic Replace fuel pump.
circuit parts.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace air breather tube
or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Lossened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
5) Clogged or bent air breather tube or air Clean, correct or replace air breather tube
vent tube. or air vent tube.
3. Gasoline smell inside of compartment
1) Loose joints at air breather tube, air vent Retightening.
tube and fuel filter pipe.
2) Defective packing air tightness on the Correct or replace packing.
fuel saucer.
3) Creacked fuel separator. Replace separator.
4) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor. Replace.
2) Defective operaiton of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration Replace.
of fuel pump.