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 notice before proceeding with work.

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  2. DISCHARGE FUEL SYSTEM PRESSURE

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  3. REMOVE BATTERY BOX COVER

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  4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

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  5. REMOVE REAR SEAT ASSEMBLY

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  6. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A0032AX

      Remove the rear floor service hole cover.

    2. A0031Z8

      Disconnect the fuel pump connector.

  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0032AWC02
      *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.

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


    1. A00323N

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

  9. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A00329J

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

  10. REMOVE FUEL PUMP GAUGE RETAINER


    1. A003225C02
      *a SST (Plate)
      *b SST (Claw)
      *c SST (Bolt)
      *d Rib

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

      SST
      09808-01071   ( 09808-01030, 09808-01050 )

      Tech Tips

      Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.

    2. While pressing SST (claws) against the fuel pump gauge retainer ribs securely, tighten SST (bolts).

      Tech Tips

      Install SST while pressing SST (claws) toward the fuel pump gauge retainer (towards the center of SST).

    3. Install SST (handle).

    4. A00322UC02
      *a SST (Handle)
      *b SST (Plate)
      *c SST (Claw)

      Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

      SST
      09808-01071   ( 09808-01010, 09808-01020, 09808-01030, 09808-01050 )

      Note


      • Do not use any tools other than specified in this operation as this may result in damage to the fuel pump gauge retainer or the fuel tank assembly.

      • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.

      • Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.

      • Do not spin SST too fast or use an impact wrench as this may result in damage to components.

      • If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.

      Tech Tips

      The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

    5. Remove the fuel pump gauge retainer while holding the fuel suction tube with pump and gauge assembly by hand.

  11. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


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

      Note

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

    2. A0031YAC02
      *1 Fuel Suction Tube Set Gasket

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