FUEL PUMP REMOVAL

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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REMOVE REAR SEAT ASSEMBLY (for Separate Seat Type)

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REMOVE REAR SEAT ASSEMBLY (for Bench Seat Type)

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REMOVE REAR FLOOR SERVICE HOLE COVER

Disconnect the rear seat inner with center belt assembly LH connector and rear seat inner with center belt assembly RH connector.
Remove the rear floor service hole cover and butyl tape.
Disconnect the fuel pump connector.

DISCHARGE FUEL SYSTEM PRESSURE

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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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DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Note:

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

*a	Retainer
*b	O-ring
*c	Fuel Tube Connector
*d	Nylon Tube
*e	Fuel Pipe
	Pinch
	Pull

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

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.
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 scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
- Do not bend, twist, pinch or kink the nylon tube.
Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

DISCONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY

Note:

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

*a	Fuel Tube Connector
*b	Fuel Pipe
*c	Retainer
*d	O-ring
	Pinch
	Pull

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

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.
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 scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

REMOVE FUEL PUMP GAUGE RETAINER

Note:

Before performing these procedures, first cover the connector and fuel tube joint 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.

*a	Paint Mark

Place paint marks on the fuel suction tube with pump and gauge assembly and vehicle body as shown in the illustration.

Note:

The fuel suction tube with pump and gauge assembly has a protrusion that engages with notch on the fuel tank assembly to ensure correct alignment and to prevent the fuel suction tube with pump and gauge assembly from turning during installation and removal of the fuel pump gauge retainer.
If the fuel pump gauge retainer is turned with the fuel suction tube with pump and gauge assembly misaligned, the fuel suction tube with pump and gauge assembly will turn with the fuel pump gauge retainer and may be damaged.
The paint marks are used to ensure that the fuel suction tube with pump and gauge assembly does not turn with the fuel pump gauge retainer.

*a	Copy of Fully Tightened Mark
*b	Copy of 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.

Copy the fully tightened mark of the fuel tank sub-assembly to the vehicle body in order to record its location.
Place a start of threads mark on the vehicle body at the position shown in the illustration.

Install SST to the fuel pump gauge retainer.

*1	Fuel Pump Gauge Retainer
*a	SST (Claw Set)
*b	Protrusion
*c	Notch
*d	Do not install SST (Claw Set)

Set 4 SST (claw set) to the fuel pump gauge retainer.

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Note:

Align the notch of SST (claw set) with the protrusion of the fuel pump gauge retainer.
Do not install SST (claw set) to the start of threads location of the fuel pump gauge retainer.

*1	Fuel Pump Gauge Retainer
*a	SST (Claw Set)
*b	Hook
	Push
	SST (Bolt)

Push SST (claw set) against the fuel pump gauge retainer and tighten SST (bolt).

*a	SST (Plate)
*b	SST (Claw Set)
	SST (Bolt)

Temporarily install SST (plate) to SST (claw set) with 4 SST (bolt).

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*a	Center Point of Fuel Pump Gauge Retainer
*b	SST (Plate)
	Front

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

*1	Fuel Pump Gauge Retainer
*a	SST (Plate)
*b	SST (Claw Set)
*c	SST (Bolt)
	Press

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

Install SST (handle) to SST (plate).

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*a	SST (Plate)
*b	SST (Handle)
*c	Fuel Pipe
	Loosen

Slowly loosen the fuel pump gauge retainer by approximately 90°.

Note:

Do not spin SST too fast or use an impact wrench as this may result in damage to components.
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.

While one person loosens the fuel pump gauge retainer, have another person press down the rising fuel suction tube with pump and gauge assembly, securely insert the protrusion of the fuel suction tube with pump and gauge assembly into the groove of the fuel tank assembly, and then remove the fuel pump gauge retainer while making sure that the fuel suction tube with pump and gauge assembly is properly aligned.

*a	SST (Plate)	*b	SST (Handle)
*c	One Person in Charge of Loosening	*d	One Person in Charge of Pressing Down
*e	Paint Mark	-	-

Note:

The fuel suction tube with pump and gauge assembly is pressed against the underside of the fuel tank 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 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 assembly may both be damaged.
Do not turn the fuel pump gauge retainer if the paint marks become misaligned.
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.

REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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

Note:
Be careful not to bend the arm of the fuel sender gauge assembly.
Remove the fuel suction tube set gasket from the fuel tank sub-assembly.