Fuel pipe / sender - what other models' can I use?

[airlia101]

(also posted on http://www.subaruoutback.org/forums/111 ... i-use.html (http://www.subaruoutback.org/forums/111-gen-1-1995-1999/48536-fuel-pipe-sender-what-other-models-can-i-use.html))

I am looking to replace both the fuel pipe and pump-side sender in my '99 SUS.
About the pipe: I'm probably going to just get it from the dealer, unless someone here has it for sale (*hint hint*!). Unless one of you can vouch for the pipe from a 05 Forester fitting... one at our junk yard has a shiney new one left in it!

The sender: I've looked on www.subarupartsforyou.com (http://www.subarupartsforyou.com) and saw that, while the driver's-side sender is the same # for 1995-1999 2.2 and 2.5, the passenger-side one had 3 or 4 variations, based on year, engine, etc. Any reason I can't use, say, the '99 2.2L sender? Or the '95 2.2&2.5 one?

Thanks!

[chuckthefuk]

There is no difference between the EJ22E and EJ25D fuel filler neck. I have a 97 GT neck in my 96 OB.

Don't buy used :-/ they will eventually fail unless its been repaired/patched.

Remove the plastic rock guard that bolts over the filler neck.. this rock guard collects dirt and debris and causes rust down the line.

You can use any Gen 2 Legacy (95-99) or Gen 1 Impreza (93-01)

A few members have used the newer style Gen 2 Impreza (02-07) with slight modifications however there are no photos or DIY for this :-(

The 05' Forester is built off a Gen 2 Impreza however there are some changes between chassis. It is doubtful that you can use the forester neck but again if the price is right your welcome to be one of the few pioneers on this topic.

Diagram w/ p/n#'s
http://opposedforces.com/parts/legacy/u ... tration_2/ (http://opposedforces.com/parts/legacy/us_b11/type_4/intake_and_supply_system_turbocharger/fuel_piping/illustration_2/)

42066AC130 '96, July — '98, May
42066AC150 '97, October — '99, May
42066FA031 '95, December — '97, July

http://opposedforces.com/parts/info/42066AC130/ <--- here u can check interchangeable chassis


Revisions happen after flaws are found with design, material, etc... so part numbers don't really matter.

If you still want to buy new check out "subarugenuineparts.com" and use the OEM parts search. Much cheaper then the dealer and sometimes better then other sites.

Hope this helps
-Chuck

oh i forgot to ask.. why do you need a new fuel sending unit?

The sending unit on the driver side is a "jet pump" or "transfer pump" it just moves fuel from one side to the other to keep the levels normal. The passenger side sending unit is the main leveler and fuel pump.

Whats ur issue?

[airlia101]

Thanks, Chuck. I get an occasional fuel scent, and a strong exhaust one, on startups. My filler pipe is going to die soon, it's caked in rust and the plastic guard was full of sand. That's not going back on. The fuel sender - I took a look at it while my trunk was stripped, and the plate it's mounted to is horribly corroded, to the point where it looks like it came from the Titanic. I got a used one which looks like it is 50,000 miles younger, which satisfies me for that. Thanks for the recommendation about the filler neck, I'm comparing prices across the various sites now.

[chuckthefuk]

I don't want to alarm you but there is a worse case scenerio which involves replacing your gas tank :-(

Over time the inlets on the tank tend to rust out but seem to be fine until you remove the filler neck which causes the inlet to break apart from trying to wiggle the rubber hose off the tank. In my situation I replaced the filler neck and 6 months later the force used to change it had stressed the rust beyond salvation...

Here is a picture of my new tank and old tank. Notice the missing inlet.
https://sl-i.net/FORUM/

https://sl-i.net/FORUM/

https://sl-i.net/FORUM/

No again this is worse case scenario.. and the job involved to replace the tank is around 8 hour at any shop.. There are ways to reduce labor time but if you are not mechanically handy I suggest you do not take on a job like this.

So moving on...

The plate that holds the sending unit can look like the titanic and still function since the rust is only skin deep :-D

https://sl-i.net/FORUM/

So now a few questions..

When you drive and have the windows open do you smell fuel?

When you said that you smell fuel on startup can you be more specific.

When you said that you smell exhaust on startup can you be more specific...
--> this has very little to do with fuel and more to do with having old exhaust gaskets or broken welds/pipes.

Sorry for the shock but its better to understand what "may" have happened before you start throwing money at your vehicle.

-Chuck

[Dead91silvia]

Again... I feel sorry for all the rust you have to put up with...

The default link to check if something interchanges....
http://car-part.com/

[airlia101]

Hm. That is a pretty unfortunate worst case. As it is, I am now most likely not bothering with the filler neck, as I'm moving off to a new job this coming week. But, give your past experience, would you recommend waiting to replace the neck until it shows failure?
Edit: Looking at mine, I thought the fuel filler would disconnect from the far end of the rubber fill hose, not the close-to-tank one. Reason for that?
My slight fuel smell I'm pretty sure is either from the exhaust (which I know darn well will need a big gasket party sometime soon =\ ), or a pinhole into the tank. On some days I'll have a lingering gas odor outside; others, I don't notice it. The exhaust smell on its own I think might be stronger at startup while either the engine runs rich or the expansion to operating temp hasn't yet sealed up the joints... does that sound reasonable?

[chuckthefuk]

Honestly .. get your fuel system smoked tested. They insert a plug with a tube that goes into your gas cap and then pump a special type of smoke into your fuel system. Any leaks will be visible by billowing smoke.

This is how I determined my gas tank was the issue. however in your case you may have smoke billow from the filler neck since as you said its at the end of its life.

I can promise you that removing a 10+ year old rubber hose from the filler neck will be difficult and will need wiggling force to remove it which will cause movement against the tank inlet. This is just assumption since I have not seen the condition of your tank or underside chassis.

-Chuck

[airlia101]

Thanks - I'll look into that.