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 notices before proceeding with work Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. REMOVE REAR NO. 2 FLOOR BOARD

    Click here

  4. REMOVE REAR DECK FLOOR BOX

    Click here

  5. REMOVE REAR NO. 3 FLOOR BOARD

    Click here

  6. REMOVE DECK FLOOR BOX RH

    Click here

  7. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE

    Click here

  8. 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.

  9. REMOVE REAR SEAT CUSHION ASSEMBLY

    Click here

  10. REMOVE REAR SEAT CUSHION LOCK HOOK

    Click here

  11. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. B001KP5

      Remove the rear floor service hole cover and butyl tape.

    2. B001L9G

      Disconnect the fuel pump connector.

  12. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B001KLRE03
      Text in Illustration
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *3 Fuel Tank Main Tube Sub-assembly
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube
      B001KHV Pull off
      B001NB3 Pull off

      Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

      Note


      • Remove any foreign matter on the fuel tube joint before performing this work.

      • 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).

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

      • Do not bend, twist, pinch or kink the nylon tube.

      • Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.

      • If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.

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


    1. B001LZF

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

  14. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. B001LRR

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

  15. DISCONNECT FUEL TANK EVAPORATION TUBE


    1. B001LZRE05
      Text in Illustration
      *a Retainer

      Release the retainer and disconnect the fuel tank evaporation tube from the fuel suction tube with pump and gauge assembly.

  16. 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.


    1. B001LIYE02
      Text in Illustration
      *a Copy of Fully Tightened Mark
      *b Copy of Start of Threads Mark
      *c Fully Tightened Mark on Fuel Tank Assembly
      *d Start of Threads Mark on Fuel Tank Assembly
      B001KHV Front

      Copy the start of threads mark and fully tightened marks from the fuel tank assembly to the vehicle body in order to record their locations.

    2. B001KSCE02
      Text in Illustration
      *a Paint Mark
      B001KHV Front

      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 2 protrusions that engage with 2 notches 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.

    3. Install SST to the fuel pump gauge retainer.


      1. B001N6EE02
        Text in Illustration
        *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.

        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 install SST (claw set) to the start of threads location of the fuel pump gauge retainer.

      2. B001LDZE02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        B001KHV Push
        B001NB3 SST (Bolt)

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

      3. B001L9FE02
        Text in Illustration
        *a SST (Plate)
        *b SST (Claw Set)
        B001KHV SST (Bolt)

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

        SST
        09808-14031   ( 09808-01030, 09808-01090 )
      4. B001M6OE01
        Text in Illustration
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        B001KHV 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.

      5. B001M50E02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        B001KHV Press

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

      6. Install SST (handle) to SST (plate).

        SST
        09808-14031   ( 09808-01010, 09808-01020 )
    4. B001N23E01
      Text in Illustration
      *a SST (Plate)
      *b SST (Handle)
      B001KHV 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.

    5. 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.

      B001MXAE02
      Text in Illustration
      *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.

  17. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B001MHH

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

      Note

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

    2. B001N74E02
      Text in Illustration
      *1 Fuel Suction Tube Set Gasket

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