7Wayne7

BTW, here's some info that may be of interest regarding the o-ring: http://www.subaruoutback.org/forums/387353-post14.html http://www.ultimatesubaru.org/forum/showpost.php?p=1118558&postcount=20

The new fuel filter cap arrived today. Installed it about an hour ago. See below for pictures of the old one as it looked upon removal of the fuel pump assembly, a side view showing the crack and the o-ring poking out a bit, the new/enlarged cap, a comparison between new and old (the interface is IDENTICAL), and a picture of the new cap installed. **Twisting on the new one was a chore! It really took some effort. You have to play around with lining up the tabs with the gaps in the right places and twist it on slowly, but surely, while putting some pretty good downward pressure on the cap. I double checked and tried to put the old one back on and it was just as hard, so I don't think this is due to different tolerances... The picture doesn't show it, but for good measure, I put a hose clamp on the outside of the tabs/clamp interface for good measure. I tightened it, but not overly so (didn't want to put undue stress on the tabs themselves, just enough to hopefully "encourage" the new o-ring not to expand enough to push out the retainer tabs of the new cap. After the dust settled, I buttoned everything up, crossed my fingers, and turned the ignition key. ...fired right up. BTW, I installed it _without_ the filter that came with the deeper cap since I already have a filter in my engine compartment (as all 2000 Outbacks do I believe). Also, I think another smaller gasket is needed between between the filter element and the fuel filter assembly, which I didn't have. Anyway, the only reason (I can think of) for these idiotic/lame/pathetic/stupidly inferior build quality metal caps on models where the filter is in the engine compartment is to cover the resevoir area that would otherwise be used for an in-tank fuel filter. Therefore I doubt there would be any difference with a larger cap with more volume. Once the resevoir fills with fuel, the pressure maintained should be the same...in theory... So far it drives just fine. Will be using it for shorter trips over the next several weeks just in case. I'll pull the filter assembly in a month to see if there is any evidence of bending of the tabs. If not, I'm probably good to go at least for the remainder of life left in the current engine. The old cap failed at ~183,000 so it lasted quite awhile as is. I am very glad not to have to procure an entire pump assembly just for this lousy cap!!!! comparison between old and new:

Yes

Thanks for posting those pics. That's EXACTLY the failure mode my metal cap experienced. Right where the 90 deg bend is between the tabs and the cap itself. Exact same location. I put a hose clamp on there and it ran fine for 4 days and then I lost pressure...

Part should be here in two days. I'll update everyone here...crossing my fingers!

I'm going off this: http://www.autopartsnetwork.com/catalog/2004/Subaru/Outback/Air_and_Fuel_Delivery/Fuel_Filter/OES_Genuine/W0133-ds-1617990.html?filter=part The attachment interface looks identical to the normal cap I have and also looks very similar to the illustrated part in the graphic. -not sure if it comes with the o-ring. If not, I can source a compatible fuel rated o-ring on Amazon for cheap.

Will do...ordering the part tonight

Thanks, much appreciated & very helpful. Looks like the illustration specific to my 2000 model year is http://opposedforces.com/parts/legacy/us_b12/type_20/intake_and_supply_system_turbocharger/fuel_tank/illustration_2/ Interestingly, in this illustration, looking closely at the part breakout for the fuel pump assembly, it appears that it is illustrated with the deeper cap and in-tank filter (see the parts listed next to #14 - this is not the shallow metal cap, but the deeper cap for the filter). This leads me to beleive that I can perhaps buy the 2004 model year in-tank filter (around $35 online) and maybe use the cap & gasket that comes with it. Hopefully the additional volume introduced to the resevoir by doing this won't have an adverse effect on fuel pressure... If that doesn't work, I could use the in-tank filter and by pass the engine compartment fuel filter I have now? Time to experiment!

Hey everyone, I have that common problem where the metal twist-on cap that goes on the resevoir on the fuel pump assembly is cracked due to the o-ring expanding too much. Looks like a few of the tabs are cracked. Anyway, I haven't been able to locate one without buying a whole new fuel pump assembly. I noticed that in 2004 or so, Subaru went with an in-tank fuel filter, with a cap that is deeper (to accomodate the filter) but it looks like the attachment interface is the same as the twist on cap I have now. Like this: http://www.autopartsnetwork.com/catalog/2004/Subaru/Outback/Air_and_Fuel_Delivery/Fuel_Filter/OES_Genuine/W0133-ds-1617990.html?filter=part name:Fuel+Filter_make:Subaru_model:Outback_year:2004_ Does anyone know if I could order that part (assuming the interface dimensions are the same) and either use just the lid/cap (since my fuel filter is in the engine compartment), or use the filter as well and then remove the filter in the engine compartment / bypass it with some tubing? Would the expanded area within that resevoir impact the fuel pressure? Anyone try this as a work-around? Thanks! Wayne

Hey everyone. There's obviously a wealth of knowledge here. Thanks for letting me join! Regards, Wayne