FUEL PUMP REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine 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.

    Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  4. REMOVE REAR SEAT CUSHION ASSEMBLY

    Click here

  5. REMOVE REAR SEAT CUSHION LOCK HOOK

    Click here

  6. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. B003U0J

      Remove the rear floor service hole cover.

    2. Disconnect the fuel pump connector.

  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B003T8HC01
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube
      B003WAF Pull Off
      B003U82 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 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 FUEL TANK RETURN TUBE


    1. B003U91C01
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube
      B003WAF Pull Off
      B003U82 Pull Off

      Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank return tube.

      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.

  9. REMOVE FUEL PUMP GAUGE RETAINER


    1. B003WORC03
      B003U82 Front Side

      Release the lock and remove the No. 1 fuel tube clamp.

    2. Remove the fuel pump gauge retainer.


      1. B003W6KC08
        *a Insertion Point
        *b SST (Plate)
        *c SST (Claw)
        *d SST (Bolt)

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

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

        Tech Tips

        Securely insert the ends of SST (claws) into the insertion points in the fuel pump gauge retainer.

      2. While firmly pressing the SST (claws) into the insertion points in the fuel pump gauge retainer, tighten the SST (bolts).

      3. Install SST (handle).

      4. B003UKLC02
        *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.

  10. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B003VJW

      Disconnect the fuel return vent tube sub-assembly.

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

      Note


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

      • Do not damage the fuel return vent tube sub-assembly.

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