FUEL PUMP REMOVAL

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 notices 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.

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  4. REMOVE REAR NO. 1 SEAT ASSEMBLY

    for 60/40 Split Seat Type LH Side: Click here

    for 60/40 Split Seat Type RH Side: Click here

  5. REMOVE DECK BOARD ASSEMBLY

    Click here

  6. REMOVE NO. 3 DECK BOARD SUB-ASSEMBLY

    Click here

  7. REMOVE DECK SIDE TRIM BOX LH

    Click here

  8. REMOVE REAR DECK FLOOR BOX

    Click here

  9. REMOVE REAR FLOOR FINISH PLATE

    Click here

  10. REMOVE TONNEAU COVER ASSEMBLY

    Click here

  11. REMOVE REAR NO. 2 SEAT ASSEMBLY

    Click here

  12. REMOVE REAR OUTER SEAT TRACK BRACKET COVER LH

    Click here

  13. REMOVE REAR DOOR SCUFF PLATE LH

    Click here

  14. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH

    Click here

  15. REMOVE REAR OUTER SEAT TRACK BRACKET COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

  16. REMOVE REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure as for the LH side.

  17. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH

    Tech Tips

    Use the same procedure as for the LH side.

  18. REMOVE FRONT DECK SIDE TRIM COVER LH

    Click here

  19. DISCONNECT REAR NO. 1 SEAT OUTER BELT ASSEMBLY LH

    Click here

  20. REMOVE NO. 2 DECK SIDE TRIM COVER

    Click here

  21. REMOVE DECK TRIM SIDE SERVICE HOLE COVER

    Click here

  22. DISCONNECT REAR NO. 2 SEAT OUTER BELT ASSEMBLY LH

    Click here

  23. REMOVE DECK TRIM POCKET COVER (for LH Side)

    Click here

  24. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (for LH Side)

    Click here

  25. REMOVE ROPE HOOK (for LH Side)

    Click here

  26. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH

    Click here

  27. REMOVE FRONT DECK SIDE TRIM COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

  28. DISCONNECT REAR NO. 1 SEAT OUTER BELT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  29. REMOVE NO. 1 DECK SIDE TRIM COVER

    Click here

  30. REMOVE DECK TRIM SIDE BELT HOLE COVER RH

    Click here

  31. DISCONNECT REAR NO. 2 SEAT OUTER BELT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  32. REMOVE SIDE TRIM COVER RH (w/o Rear Automatic Air Conditioning System)

    Click here

  33. REMOVE COOLER (NO. 2 ROOM TEMP. SENSOR) THERMISTOR (w/ Rear Automatic Air Conditioning System)

    Click here

  34. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

    Click here

  35. REMOVE DECK TRIM POCKET COVER (for RH Side)

    Tech Tips

    Use the same procedure as for the LH side.

  36. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (for RH Side)

    Tech Tips

    Use the same procedure as for the LH side.

  37. REMOVE ROPE HOOK (for RH Side)

    Tech Tips

    Use the same procedure as for the LH side.

  38. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH

    Click here

  39. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A002A44

      Turn back the front floor carpet.

    2. A002AYSC01
      *a Protective Tape

      Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.

    3. Disconnect the 2 fuel pump connectors.

  40. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A002A2TC01
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube
      B003ZIE Pull off
      B003Z8F 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.

  41. REMOVE FUEL PUMP GAUGE RETAINER

    Note

    Before performing these procedures, first cover the connectors 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. Install SST (fuel pump holding tool assy) to the fuel pump gauge retainer.


      1. Insert SST (claw No. 1) between the service hole and fuel pump gauge retainer as shown in the illustration.

        A002C60C01
        *a SST (Claw No. 1) *b Wide
        SST
        09808-14050   ( 09882-14050 )

      2. Align the detent of the tank suction tube support and cutout of SST (claw No. 1).

        A0029SIC01
        *a SST (Claw No. 1) *b Detent of Tank Suction Tube Support
        B003ZIE Front - -

      3. Insert SST (claw) between the service hole and fuel pump gauge retainer as shown in the illustration.

        A0029XUC01
        *a SST (Claw No. 1) *b SST (Claw)
        SST
        09808-14040   ( 09882-14040 )

      4. Insert SST (claw No. 2) between the service hole and fuel pump gauge retainer, and align it with the second detent of the tank suction tube support.

        A002C1QC01
        *a SST (Claw No. 1) *b SST (Claw No. 2)
        *c SST (Bridge) *d SST (Bolt)
        *e Narrow *f Contact
        *g Cloth *h Detent of Tank Suction Tube Support
        SST
        09808-14050   ( 09881-14050, 09882-14050, 09883-14050, 09884-14050 )

      5. Install SST (bridge) to SST (claw No. 1) and SST (claw No. 2) with 2 SST (bolt).

      6. Place a piece of cloth or equivalent on the fuel suction tube with pump and gauge assembly and lightly tighten 2 SST (bolt) of SST (bridge) until they come into contact with the fuel suction tube with pump and gauge assembly.

        Note

        If a piece of cloth or equivalent is not placed between the fuel suction tube with pump and gauge assembly and 2 SST (bolt), the fuel suction tube with pump and gauge assembly may be damaged.

    2. Install SST (fuel pump retainer tool assy) to the fuel pump gauge retainer.


      1. Position SST (claw) next to SST (claw No. 1) so that the protrusions of the fuel pump gauge retainer are aligned with the grooves of SST (claw). Insert the second SST (claw) between the service hole and fuel pump gauge retainer, and position it next to SST (claw No. 2) so that it is opposite to SST (claw), and the protrusions of the fuel pump gauge retainer are aligned with the grooves of SST (claw).

        A002733C01
        *a SST (Claw No. 1) *b SST (Claw No. 2)
        *c SST (Claw) *d SST (Bridge)
        *e Triangle Mark *f Protrusion of Fuel Pump Gauge Retainer
        *g Groove of SST (Claw) *h Correct
        *i Incorrect - -
        SST
        09808-14040   ( 09882-14040 )

        Note

        Ensure that SST (claw) does not cover the triangle mark of the fuel pump gauge retainer.

      2. A0027BOC01
        *a SST (Claw No. 1)
        *b SST (Claw No. 2)
        *c SST (Claw)
        *d SST (Bridge)
        *e SST (Plate)
        *f SST (Bolt and Washer Set)

        While ensuring that SST (plate) is centered, install SST (plate) to 2 SST (claw) with 2 SST (bolt and washer set).

        SST
        09808-14040   ( 09881-14040, 09883-14040 )
    3. A002BQ1C01
      *a SST (Fuel Pump Holding Tool Assy)
      *b SST (Fuel Pump Retainer Tool Assy)

      Attach 2 breaker bars to SST (fuel pump holding tool assy) and 1 breaker bar to SST (fuel pump retainer tool assy).

    4. A0027JYC01
      *a Paint Mark

      Place paint marks on the fuel suction tube with pump and gauge assembly, fuel pump gauge retainer and fuel tank assembly as shown in the illustration.

    5. While holding the 2 breaker bars attached to SST (fuel pump holding tool assy), turn the breaker bar attached to SST (fuel pump retainer tool assy) to loosen the fuel pump gauge retainer. [*1]

      A002CFZC02
      *a SST (Fuel Pump Holding Tool Assy) *b SST (Fuel Pump Retainer Tool Assy)
      *c Holding *d Push down
      *e Turn - -

      Note

      Push down on the 2 locations shown in the illustration to prevent SST (fuel pump holding tool assy) from turning.

    6. Check that only the paint mark on the fuel pump gauge retainer has moved.

      A002A7JC01
      *a Paint Mark *b Correct
      *c Incorrect - -

      Tech Tips

      If the paint mark on the fuel suction tube with pump and gauge assembly has also moved, tighten the fuel pump gauge retainer until the paint marks are aligned at the original position. Then repeat from step [*1].

    7. Loosen the fuel pump gauge retainer by using SST (fuel pump retainer tool assy) until the fuel pump gauge retainer turns approximately 360°.

      A002834C01
      *a SST (Claw) *b SST (Fuel Pump Holding Tool Assy)
      *c SST (Fuel Pump Retainer Tool Assy) - -

    8. Remove SST (fuel pump retainer tool assy) and SST (fuel pump holding tool assy) from the fuel pump gauge retainer.

    9. Check that the fuel pump gauge retainer can be loosened by hand.

      SST
      09808-14040   ( 09881-14040, 09882-14040, 09883-14040 )

    10. While holding the fuel suction tube with pump and gauge assembly by hand, remove the fuel pump gauge retainer.

  42. 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

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

    2. A0029SYC01
      *1 Fuel Suction Tube Set Gasket

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