FUEL PUMP REMOVAL

PROCEDURE


  1. REMOVE REAR BENCH TYPE SEAT CUSHION ASSEMBLY (for Sedan)

    Click here

  2. REMOVE REAR BENCH TYPE SEAT CUSHION ASSEMBLY (for Wagon)

    Click here

  3. REMOVE NO. 1 QUARTER WHEEL HOUSE GUSSET SUB-ASSEMBLY

    Click here

  4. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A0056D6

      Remove the rear floor service hole cover.

    2. Disconnect the connector from the fuel suction with pump assembly.

  5. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge fuel system pressure Click here.

  6. PRECAUTION

    Note

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

  7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  8. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0054SUE01
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring

      Remove the tube joint clip and pull the fuel tube joint out of the plug of the fuel suction with pump 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 the fuel tube joint with a plastic bag.

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


    1. A00543N

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

  10. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A0056AU

      Disconnect the No. 1 charcoal canister outlet hose from the fuel suction with pump assembly.

  11. DISCONNECT NO. 2 FUEL TANK EVAPORATION TUBE


    1. A0055JBE01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the No. 2 fuel tank evaporation tube from the fuel suction with pump assembly.

  12. REMOVE FUEL PUMP GAUGE RETAINER

    Note

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


    1. A0054VSE01
      Text in Illustration
      *a Co-rotation Prevention Check Mark
      A0054DN Front Side of Vehicle

      Apply a co-rotation prevention check mark to the fuel suction with pump and gauge tube assembly and vehicle body.

      Note


      • The fuel suction with pump and gauge tube assembly has 2 protrusions that engage with 2 notches on the fuel tank assembly to ensure correct alignment and to prevent the fuel suction with pump and gauge tube 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 with pump and gauge tube assembly misaligned, the fuel suction with pump and gauge tube assembly will turn with the fuel pump gauge retainer and may be damaged.

      • Make sure to apply a co-rotation prevention check mark to prevent the fuel suction with pump and gauge tube assembly from co-rotating.

    2. A0054BQE02
      Text in Illustration
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Rib
      *c Cutout
      *d SST (Claw Set) Incorrect Installation Point (Rotational Start Point Mark of Fuel Pump Gauge Retainer)

      Install SST to the fuel pump gauge retainer.


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

        SST
        09808-14031   ( 09808-01080, 09808-01090, 09808-01100 )

        Note


        • Align the notch of SST (claw set) with the protrusion of the fuel pump gauge retainer.

        • Do not place SST on the rotational start point mark of the fuel pump gauge retainer, otherwise SST (claw set) cannot be set correctly.

      2. A0057LME02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        A0054DN Press
        A0057VO SST (Bolt)

        While firmly pressing the claw of SST against the rib of the fuel pump gauge retainer, tighten the bolt.

      3. A0057S0E02
        Text in Illustration
        *a SST (Plate)
        *b SST (Claw Set)
        A0054DN SST (Bolt)

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

        SST
        09808-14031   ( 09808-01090, 09808-01030 )
      4. A00575XE02
        Text in Illustration
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        A0054DN Front Side of Vehicle

        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.

      5. A00567GE02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        A0054DN Press

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

      6. A00541RE02
        Text in Illustration
        *a SST (Plate)
        *b SST (Handle)
        A0054DN Loosen

        Install SST (handle) to SST (plate).

        SST
        09808-14031   ( 09808-01010, 09808-01020 )

    3. 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.

      • Do not use any tools other than SST, such as a screwdriver, etc.

      • Do not use excessive force when pressing down on SST, as the fuel pump gauge retainer will place excessive force on the fuel suction tube assembly with pump and gauge and be difficult to remove, and parts may be damaged.

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

      A0057DEE02
      Text in Illustration
      *a SST (Plate) *b SST (Handle)
      *c Person in Change of Loosening *d Person in Charge of Pressing Down
      *e Co-rotation Prevention Check Mark - -

      Note


      • The fuel suction with pump and gauge tube 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 with pump and gauge tube assembly to rise up.

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

      • Do not rotate the fuel pump gauge retainer when the co-rotation prevention check mark is out of place.

      • Be careful not to bend the arm of the fuel sender gauge assembly.

  13. REMOVE FUEL SUCTION WITH PUMP ASSEMBLY


    1. Remove the fuel suction with pump assembly from the fuel tank.

      Note

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

    2. A00552VE05
      Text in Illustration
      *1 Gasket

      Remove the gasket from the fuel tank.