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 notices before proceeding with work.

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  2. DISCHARGE FUEL SYSTEM PRESSURE

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  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 SEAT CUSHION ASSEMBLY

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  5. REMOVE REAR SEAT CUSHION LOCK HOOK

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  6. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. B0077N5C02
      *a Protective Tape

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

    2. B0076XE

      Disconnect the 2 fuel pump connectors.

  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B0073MDC02
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *3 Fuel Tank Main Tube Sub-assembly
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube
      B0073AQ Pull off
      B0077IM 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.

  8. REMOVE FUEL PUMP GAUGE RETAINER


    1. B00751RC02
      B0077IM Front Side

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

    2. Remove the fuel pump gauge retainer.


      1. B007405C12
        *a Insertion Point
        *b SST (Plate)
        *c SST (Claw)
        *d SST (Bolt)

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

        SST
        09808-14031   ( 09808-01030, 09808-01040, 09808-01050 )

        Tech Tips

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

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

      3. B0077XYC05
        *a SST (Handle)
        *b SST (Plate)
        *c SST (Claw)
        *d SST (Bolt)

        Install SST (handle) to SST (plate).

        SST
        09808-14031   ( 09808-01010, 09808-01030, 09808-01040, 09808-01050 )

      4. 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.

        Note


        • Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or 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 (bolt) and reinstall SST.

      5. While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.

  9. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B00756R

      Disconnect the fuel return vent tube sub-assembly and 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.

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

      • When disconnecting the fuel tube connector, do not excessively pull on the fuel return vent tube sub-assembly.

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