FUEL PUMP REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

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

  2. REMOVE REAR NO. 1 SEAT ASSEMBLY (for Side)

    Click here

  3. REMOVE REAR NO. 1 SEAT ASSEMBLY (for Center)

    Click here

  4. REMOVE REAR NO. 2 SEAT ASSEMBLY

    Click here

  5. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. B005YFZ

      Using a clip remover, remove the 2 clips.

    2. Turn over the front floor carpet.

    3. B005Z59

      Remove the rear floor service hole cover.

    4. B005Y8Q

      Disconnect the connector from the fuel suction tube assembly.

  6. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  7. REMOVE DECK BOARD ASSEMBLY

    Click here

  8. REMOVE NO. 1 DECK BOARD

    Click here

  9. REMOVE NO. 2 DECK BOARD

    Click here

  10. REMOVE REAR DECK FLOOR BOX

    Click here

  11. REMOVE DECK FLOOR BOX RH

    Click here

  12. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  13. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B005Z63E02
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tube Joint
      *3 O-ring

      Remove the tube joint clip, then pull the fuel tube joint out of the plug of the fuel suction tube with pump and gauge assembly.

      Note


      • Check that there is no dirt or other foreign objects around the fuel tube joint before disconnecting it. Clean the joint if necessary.

      • It is necessary to prevent mud or dirt from entering the joint. If mud or dirt gets in the joint, the O-rings may not seal properly.

      • Only disconnect the joint by hand.

      • Do not bend, kink or twist the nylon tubes.

      • Protect the contact surfaces by covering it with a plastic bag.

  14. DISCONNECT CHARCOAL CANISTER OUTLET HOSE


    1. B005Y89

      Disconnect the charcoal canister outlet hose from the fuel suction tube with pump and gauge assembly.

  15. DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. B005XLH

      Loosen the clip and disconnect the No. 1 fuel evaporation tube sub-assembly from the fuel suction tube with pump and gauge assembly.

  16. REMOVE FUEL PUMP GAUGE RETAINER


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      Text in Illustration
      *1

      SST

      (Plate)
      *2

      SST

      (Claw)
      *3 Rib

      Temporarily install the SST plate and claws to the fuel pump gauge retainer.

      SST
      09808-14030   ( 09808-01030, 09808-01040, 09808-01050 )

      Tech Tips

      Engage the SST claws securely with the fuel pump gauge retainer ribs to secure SST.

    2. While pressing the claws of SST to the fuel pump gauge retainer ribs securely, tighten the bolts.

      Tech Tips

      Install SST while pressing the SST claws toward the fuel pump gauge retainer (towards the center of SST).

    3. Install the SST handle.

    4. B005YGKE04
      Text in Illustration
      *1

      SST

      (Handle)
      *2

      SST

      (Plate)
      *3

      SST

      (Claw)

      Lightly press down on SST to prevent it from separating from the retainer. While pressing SST, rotate the handle slowly to loosen the retainer.

      SST
      09808-14030   ( 09808-01010, 09808-01020, 09808-01030, 09808-01040, 09808-01050 )

      Note


      • Do not use any tools other than specified in this operation as this may result in damage to the fuel pump gauge retainer or the fuel tank.

      • Do not press down on SST excessively as this may make the retainer hard to rotate, and may damage components.

      • Make sure to rotate the SST handle horizontally. If the SST handle is rotated at an angle, SST may come off.

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

      • If SST comes off of the retainer, loosen the SST bolts and reinstall SST.

      Tech Tips

      The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

    5. Remove the fuel pump gauge retainer while holding the fuel suction tube with pump and gauge assembly by hand.

  17. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


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

      Note

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

    2. B005ZJXE01
      Text in Illustration
      *1 Fuel Suction Tube Set Gasket

      Remove the fuel suction tube set gasket from the fuel tank.