FUEL PUMP REMOVAL

PROCEDURE


  1. REMOVE REAR BENCH TYPE SEAT CUSHION ASSEMBLY


  2. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. Remove the butyl tape and rear floor service hole cover.

    2. A004QA2

      Disconnect the fuel suction with pump and gauge tube assembly connector.

  3. DISCONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A004RTNE02
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Suction with Pump and Gauge Tube Assembly
      *5 Nylon Tube

      Remove the tube joint clip and pull out the fuel tank return tube sub-assembly.

      Note


      • Remove any dirt and foreign matter on the fuel tube joint before performing this step.

      • Do not scratch or allow any foreign matter to adhere to the parts when disconnecting them as the fuel tube joint contains the O-rings that seal the plug.

      • Perform this step by hand. Do not use any tools.

      • Do not forcibly bend or twist the nylon tube.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube.

  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A004O4ZE02
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Suction with Pump and Gauge Tube Assembly
      *5 Nylon Tube

      Remove the tube joint clip and pull out the fuel tank main tube sub-assembly.

      Note


      • Remove any dirt and foreign matter on the fuel tube joint before performing this step.

      • Do not scratch or allow any foreign matter to adhere to the parts when disconnecting them as the fuel tube joint contains the O-rings that seal the plug.

      • Perform this step by hand. Do not use any tools.

      • Do not forcibly bend or twist the nylon tube.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube.

  5. DISCONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY (w/ Combustion Type Power Heater)


    1. A004RHWE02
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Suction with Pump and Gauge Tube Assembly
      *5 Nylon Tube

      Remove the tube joint clip and pull out the No. 2 fuel tank main tube sub-assembly.

      Note


      • Remove any dirt and foreign matter on the fuel tube joint before performing this step.

      • Do not scratch or allow any foreign matter to adhere to the parts when disconnecting them as the fuel tube joint contains the O-rings that seal the plug.

      • Perform this step by hand. Do not use any tools.

      • Do not forcibly bend or twist the nylon tube.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube.

  6. REMOVE TANK SUCTION TUBE SUPPORT


    1. A004REG

      Press on the tabs from both sides of the fuel tube clamp.

    2. Pull the tank suction tube support in the direction indicated by the arrow in the illustration.

    3. A004Q0X

      Detach the 2 claws and remove the tank suction tube support.

  7. REMOVE FUEL PUMP GAUGE RETAINER

    CAUTION:

    Due to swelling of the fuel tank assembly, the tightening torque of the fuel pump gauge retainer may be as high as 200 N*m (2039 kgf*cm, 148 ft.*lbf), so perform the procedure with at least 2 people.

    Note

    Before performing these procedures, first cover the connectors and tube joints of the fuel suction with pump and gauge tube assembly with vinyl tape, and then clean away any mud or other substances that may be adhering in order to prevent foreign matter from contaminating the fuel system.


    1. A004SB9E01
      Text in Illustration
      *1 Fuel Pump Gauge Retainer
      *a CORRECT
      *b INCORRECT
      *c SST (Claw)

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

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

      Note

      Install SST (claw) to the correct location.

    2. A004TKRE04
      Text in Illustration
      *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. A004QR1E01
      Text in Illustration
      *a SST (Plate)
      *b SST (Claw)
      *c SST (Bolt)
      A004NPW Press

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

    4. A004RJ4E03
      Text in Illustration
      *a SST (Handle)
      *b SST (Plate)
      *c Worker A
      *d Worker B
      A004NPW Hold Down
      A004NAK Slowly Rotate

      Install SST (handle) to SST (plate).

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

    5. To make sure SST does not separate from the fuel pump gauge retainer, one person should hold down the center of SST from above while at the same time both people slowly rotate 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 with pump and gauge tube assembly or fuel tank assembly.

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

      • 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.

    6. A004QJ0E02
      Text in Illustration
      *a SST (Handle)
      *b SST (Plate)
      *c Worker A
      *d Worker B
      A004NPW Press Down
      A004NAK Slowly Rotate

      While one person presses down to prevent the fuel pump gauge retainer and fuel suction with pump and gauge tube assembly from rotating together, the other person should slowly rotate SST (handle) and remove the fuel pump gauge retainer from the fuel tank assembly.

      CAUTION:

      Make sure not to pinch your hands with SST.

      Note

      If the fuel pump gauge retainer is turned while the fuel suction with pump and gauge tube assembly and fuel tank assembly are not fully engaged, 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 the fuel tank assembly will both be damaged.

  8. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


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

      Note

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

    2. A004NQAE01
      Text in Illustration
      *1 Gasket

      Remove the gasket from the fuel tank assembly.

  9. REMOVE FUEL SENDER GAUGE ASSEMBLY

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