FUEL PUMP(for 5 Door) REMOVAL

PROCEDURE


  1. REMOVE FUEL TANK SUB-ASSEMBLY

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  2. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Note

    Protect the connector and tube joint of the fuel suction with pump and gauge tube assembly with vinyl tape to prevent foreign matter from entering. Then clean off any mud or other foreign matter before proceeding with work.


    1. B001H51C02
      *a Co-rotation Prevention Check Mark

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

      Note


      • The fuel tank sub-assembly cutout is attached to the protrusion on the fuel suction with pump and gauge tube assembly.

      • If the fuel suction with pump and gauge tube assembly and fuel tank sub-assembly are not firmly attached and the fuel pump gauge retainer is rotated, the fuel suction with pump and gauge tube assembly will co-rotate and result in the fuel suction with pump and gauge tube assembly and fuel tank sub-assembly being 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. B001GAWC01
      *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)

      Set 4 SSTs (claw sets) to the fuel pump gauge retainer and temporarily install.

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

      Note


      • Align the cutout of SST (claw set) to the rib 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.

    3. B001GYSC02
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Hook
      B001CHY Press
      B001DEF SST (Bolt)

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

    4. B001GNDC02
      *a SST (Plate)
      *b SST (Claw Set)
      B001CHY SST (Bolt)

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

      SST
      09808-14031   ( 09808-01030, 09808-01090 )
    5. B001F2IC02
      *a Center of Fuel Pump Gauge Retainer
      *b SST (Plate)

      Adjust the position of SST (plate) so that the setting hole of SST (handle) aligns with the center of the fuel pump gauge retainer.

    6. B001G7GC01
      *1 Fuel Pump Gauge Retainer
      *a SST (Plate)
      *b SST (Claw Set)
      *c SST (Bolt)
      *d Rib
      B001DLW Press

      While firmly pressing the SST (claw set) into rib of the fuel pump gauge retainer, tighten SST (bolt).

    7. B001FKEC03
      *a SST (Plate)
      *b SST (Handle)
      B001CHY Loosen

      Install SST (handle) to SST (plate).

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

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

      Note


      • 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 suction with pump and gauge tube assembly will place excessive force on the pump gauge retainer and be difficult to remove, and parts may be damaged.

      • Do not use an impact wrench or turn the SST handle with excessive force, as parts may be damaged.

    9. While one person slowly loosens the fuel pump gauge retainer, have another person press down the rising fuel suction with pump and gauge tube assembly, securely attach the protrusion of the fuel suction with pump and gauge tube assembly to the groove of the fuel tank sub-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.

      B001GYPC02
      *a SST (Plate) *b SST (Handle)
      *c Person in Charge of Loosening *d Person in Charge of Supporting
      *e Co-rotation Prevention Check Mark - -

      Note


      • The fuel suction with pump and gauge tube assembly is equipped with a spring that pushes against the bottom of the fuel tank sub-assembly to constantly lift the fuel suction with pump and gauge tube assembly upwards.

      • If the fuel suction with pump and gauge tube assembly and fuel tank sub-assembly are not firmly attached and the fuel pump gauge retainer is rotated, the fuel suction with pump and gauge tube assembly will co-rotate and result in the fuel suction with pump and gauge tube assembly and fuel tank sub-assembly being damaged.

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

      • Do not bend the arm of the fuel sender gauge assembly.

    10. Remove the gasket from the fuel tank sub-assembly.