FUEL PUMP REMOVAL

PROCEDURE

  1. PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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  2. REMOVE REAR SEAT ASSEMBLY (for Separate Seat Type)

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  3. REMOVE REAR SEAT ASSEMBLY (for Bench Seat Type)

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  4. REMOVE REAR FLOOR SERVICE HOLE COVER

    1. A322303

      Disconnect the rear seat inner with center belt assembly LH connector and rear seat inner with center belt assembly RH connector.

    2. A322280

      Remove the rear floor service hole cover and butyl tape.

    3. Disconnect the fuel pump connector.

  5. DISCHARGE FUEL SYSTEM PRESSURE

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  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    Note:

    Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.

    1. A322304C01

      *a

      Retainer

      *b

      O-ring

      *c

      Fuel Tube Connector

      *d

      Nylon Tube

      *e

      Fuel Pipe
      V100135

      Pinch
      V100136

      Pull

      Disconnect the fuel tank main tube sub-assembly from the fuel suction tube with pump and gauge assembly.

      1. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note:

        • Be sure to disconnect the fuel tube connector by hand.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

        • Do not forcibly bend, twist or turn the nylon tube.

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  8. DISCONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY

    Note:

    Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.

    1. A322306C01

      *a

      Fuel Tube Connector

      *b

      Fuel Pipe

      *c

      Retainer

      *d

      O-ring
      V100135

      Pinch
      V100136

      Pull

      Disconnect the No. 1 fuel emission tube sub-assembly from the fuel suction tube with pump and gauge assembly.

      1. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note:

        • Be sure to disconnect the fuel tube connector by hand.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the fuel pipe.

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  9. REMOVE FUEL PUMP GAUGE RETAINER

    Note:

    Before performing these procedures, first cover the connector and fuel tube joints of the fuel suction tube with pump and gauge assembly with vinyl tape and then clean any dirt and foreign matter in order to prevent contamination of the fuel system.

    1. A322311C01

      *a

      Copy of Fully Tightened Mark

      *b

      Start of Threads Mark

      *c

      Fully Tightened Mark on Fuel Tank Sub-assembly

      *d

      100°

      Copy the fully tightened mark of the fuel tank sub-assembly and place a start of threads mark.

      1. Copy the fully tightened mark of the fuel tank sub-assembly to the vehicle body in order to record its location.

      2. Place a start of threads mark on the vehicle body at the position shown in the illustration.

    2. Install SST to the fuel pump gauge retainer.

      1. A315537C02

        *1

        Fuel Pump Gauge Retainer

        *a

        SST (Claw)

        *b

        SST (Plate)

        *c

        SST (Bolt)

        *d

        Correct

        *e

        Incorrect

        *f

        Do not install SST (Claw)

        Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

        09808-14030

        09808-01030

        09808-01040

        09808-01020

        Note:

        • Install SST (claw) to the correct location.

        • Do not install SST (claw) to the start of threads location of the fuel pump gauge retainer.

      2. A309772C01

        *a

        Center Point of Fuel Pump Gauge Retainer

        Adjust the position of SST (claw) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.

      3. Press SST (claw) against the rib of the fuel pump gauge retainer and tighten SST (bolt).

      4. A331597C01

        *a

        SST (Claw)

        *b

        SST (Plate)

        *c

        SST (Bolt)

        *d

        SST (Handle)

        *e

        Fuel Pipe

        *f

        Press down

        *g

        Pull

        Install SST (handle) to SST (plate).

        09808-14030

        09808-01010

        09808-01020

        09808-01030

        09808-01040

        09808-01050

        Note:

        The torque required to remove the fuel pump gauge retainer may be as high as 200 N*m (2039 kgf*cm, 148 ft.*lbf) due to swelling of the fuel tank sub-assembly, so perform the procedure with 2 people.

    3. While pressing down on the center of SST (handle) to prevent SST from separating from the fuel pump gauge retainer, pull SST (handle) with another person pulling the opposite end of SST (handle), and slowly loosen the fuel pump gauge retainer by approximately 90°.

      Note:

      • Be careful not to apply excessive downward force to SST, as this may damage the fuel suction tube with pump and gauge assembly or fuel tank sub-assembly.

      • Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so be sure SST is horizontal when turning.

      • To prevent damage to parts, do not turn SST too vigorously.

      • If SST slips off of the fuel pump gauge retainer, loosen SST (bolt) and install SST again.

      • As the fuel pipes protrude above the fuel pump gauge retainer , SST should be removed and set as necessary to prevent it from contacting the pipes when removing the fuel pump gauge retainer.

    4. A309805C05

      *a

      SST (Claw)

      *b

      SST (Plate)

      *c

      SST (Bolt)

      *d

      SST (Handle)

      *e

      One Person in Charge of Loosening

      *f

      One Person in Charge of Pressing Down

      Continue to slowly loosen the fuel pump gauge retainer while another person is pressing down on the fuel suction tube with pump and gauge assembly to keep the protrusion of the fuel suction tube with pump and gauge assembly engaged with the groove of the fuel tank sub-assembly so that the fuel suction tube with pump and gauge assembly does not move out of position.

      Note:

      • The fuel suction tube with pump and gauge assembly is pressed against the underside of the fuel tank sub-assembly by a spring, and the constant upward pressure applied by this spring causes the fuel suction tube with pump and gauge assembly to rise up.

      • If the fuel pump gauge retainer is turned while the fuel suction tube with pump and gauge assembly and fuel tank sub-assembly are not correctly aligned, the fuel suction tube with pump and gauge assembly will move with the fuel pump gauge retainer, and the fuel suction tube with pump and gauge assembly and fuel tank sub-assembly may both be damaged.

      • As the fuel pipes protrude above the fuel pump gauge retainer , SST should be removed and set as necessary to prevent it from contacting the pipes when removing the fuel pump gauge retainer.

  10. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    1. A322308

      Remove the fuel suction tube with pump and gauge assembly from the fuel tank sub-assembly.

      Note:

      Make sure that the fuel sender gauge assembly arm does not bend.

    2. Remove the fuel suction tube set gasket from the fuel tank sub-assembly.