FUEL PUMP REMOVAL

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the fuel pump.

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PROCEDURE


  1. PRECAUTION

    Note

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

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  2. REMOVE REAR SEAT CUSHION ASSEMBLY

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  3. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A002ZWO

      Disconnect the 2 connectors.

    2. A002ZZP

      Remove the butyl tape and rear floor service hole cover.

    3. Disconnect the fuel pump connector.

  4. DISCHARGE FUEL SYSTEM PRESSURE

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  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A002ZP0C01
      *1 Tube Joint Clip
      *2 Fuel Suction Plate Sub-assembly
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube

      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 allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has O-rings that seal the fuel pipe.

      • Only disconnect the fuel tube joint by hand.

      • Do not forcibly bend, twist or turn the nylon tube.

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

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

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


    1. A0030II

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

  8. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE

    A0031BA

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

  9. DISCONNECT NO. 2 FUEL TANK EVAPORATION TUBE


    1. A00305AC01
      *a Fuel Pump Gauge Retainer

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

  10. REMOVE FUEL PUMP GAUGE RETAINER

    Note

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


    1. Install SST to the fuel pump gauge retainer.


      1. A0030LYC01
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw)
        *b Correct
        *c Incorrect

        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. A003068C01
        *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. Press SST (claw) against the rib of the fuel pump gauge retainer and tighten SST (bolt).

      4. Install SST (handle).

        Note

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

    2. A002ZX0C01
      *a Hold Down
      *b Pull

      While holding down on the center of SST (handle) to prevent SST from separating from the fuel pump gauge retainer, pull SST (handle) with another person pulling the opposite end of SST (handle), and slowly loosen the fuel pump gauge retainer by approximately 90°.

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

      Note


      • Be careful not to apply excessive downward force to SST, as this may damage the fuel pump or fuel tank assembly.

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

      • 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.

    3. A0030M2C01
      *a One Person in Charge of Loosening
      *b One Person in Charge of Holding

      Continue to slowly loosen the fuel pump gauge retainer while another person is pressing down on the fuel pump to keep the protrusion of the fuel pump engaged with the groove of the fuel tank assembly so that the fuel pump does not move out of position.

      Note


      • The fuel pump 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 pump to rise up.

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

  11. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


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

      Note

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

    2. A002ZN4C01
      *1 Fuel Suction Tube Set Gasket

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

    3. Copy the fully tightened mark and start of threads mark of the fuel tank assembly.


      1. A002ZPGC01
        *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
        *e Front

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