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Old 07-11-2010, 11:10 AM   #1
Scooby Newbie
Member#: 4014
Join Date: Feb 2001
Location: Ithaca, New York, USA
Default fuel filler neck

My 2000 Impreza RS is starting to suffer from ten years of exposure to the salt on the roads in the northeast US. The fuel filler neck is rusted completely through. Likely related to this problem, the fuel gauge is wacky, saying the tank is empty when it's not.
A new filler neck is about $130, and the associated widget for installing the small pipes near it is another $75, or so. I bought a piece of 1 1/2" fuel line and plan to cut out the filler neck where it is rusted and simply clamp the rubber hose on to the solid parts of the neck.
Is there anything that I should be aware of? I know working around fuel is dangerous, and I'm a little apprehensive of using a hack saw on the fuel filler neck. I think I can saw the pipe without causing a spark, though.
Any comments on my plan for repairing the pipe are appreciated.
Randy Olson
Ithaca, NY
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Old 07-11-2010, 11:33 AM   #2
Scooby Newbie
Member#: 192709
Join Date: Oct 2008
Chapter/Region: W. Canada
Location: Calgary, AB CANADA
2007 2.5iSE Wagon CG
2001 2.5RS Coupe RBP


Don't get a bunch of metal filings in your fuel tank. A full fuel tank is less likely to light off than an empty tank.

Pull your fuel sender and sand down the contacts on the wiper rheostat. That should fix your indicating issue.
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Old 07-11-2010, 11:34 AM   #3
Scooby Specialist
Member#: 73636
Join Date: Nov 2004
Chapter/Region: E. Canada
Location: the 'wa, ontario, canada
2017 WRX base
Urban Grey


sparks won't be your issue in changing the neck... most likely the body around the fuel door and underneath the plastic bits of the fuel filler will be rotted pretty badly from the inside out. We had a club member rebuild and swap a 98 wagon. It looked pretty decent on the outside but the most rust was at that corner from inside the filler port and in the body itself under the rear quarter metal.
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Old 07-12-2010, 06:37 AM   #4
Scooby Newbie
Member#: 4014
Join Date: Feb 2001
Location: Ithaca, New York, USA

Yesterday I cut the rusted portion of the filler pipe out and cobbed together a section of rubber hose, including clamps, and sealant. It didn't work. There was too much rust on the pipe, the hole extended up to where the pipe ended which made it hard to get the rubber hose over it, and the whole enchilada leaked when we poured gas in.
I plan to go to the Subaru dealer today and pick up the filler neck. Cost is about $150. I know I could probably get one cheaper on the net, but I want the car tomorrow for a trip.
The dealer said I would probably need another bracket they sell for about $75. He said the 8 mm screws on it usually rusted out. If he's talking about the three screws that are visible when the fuel door is open, then I may be ok, because I removed them successfully already. Any ideas about what he's talking about?
The other thing that's still puzzling is the three small tubes along side the large filler neck. One is obviously an overfill pipe that drain fuel back to the tank. The other two are mysteries. Any ideas?
By the way, a good clue might be the fuel gauge seems to registering empty now. Maybe it's because one of those small tubes is completely disconnected at the top due to rust.
Any help is appreciated.
Randy Olson
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