FUEL PUMP REMOVAL
CAUTION / NOTICE / HINT
PROCEDURE
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.
REMOVE REAR SEAT CUSHION ASSEMBLY
REMOVE REAR FLOOR SERVICE HOLE COVER
-
Disconnect the 2 connectors.
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Remove the butyl tape and rear floor service hole cover.
Disconnect the fuel pump connector.
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DISCHARGE FUEL SYSTEM PRESSURE
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Note:When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
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*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.
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DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY
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Slide the clip and disconnect the No. 1 fuel evaporation tube sub-assembly from the fuel suction tube with pump and gauge assembly.
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DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE
Disconnect the No. 1 charcoal canister outlet hose from the fuel suction tube with pump and gauge assembly.
DISCONNECT NO. 2 FUEL TANK EVAPORATION TUBE
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*a
Retainer
Release the retainer and disconnect the No. 2 fuel tank evaporation tube from the fuel suction tube with pump and gauge assembly.
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REMOVE FUEL PUMP GAUGE RETAINER
Note:Before performing these procedures, first cover the connector 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.
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*a
Paint Mark
Front
Place paint marks on the fuel suction tube with pump and gauge assembly and vehicle body as shown in the illustration.
Note:The fuel suction tube with pump and gauge assembly has 2 protrusions that engage with 2 notches on the fuel tank assembly to ensure correct alignment and to prevent the fuel suction tube with pump and gauge assembly from turning during installation and removal of the fuel pump gauge retainer.
If the fuel pump gauge retainer is turned with the fuel suction tube with pump and gauge assembly misaligned, the fuel suction tube with pump and gauge assembly will turn with the fuel pump gauge retainer and may be damaged.
The paint marks are used to ensure that the fuel suction tube with pump and gauge assembly does not turn with the fuel pump gauge retainer.
Install SST to the fuel pump gauge retainer.
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*1
Fuel Pump Gauge Retainer
*a
SST (Claw Set)
*b
Protrusion
*c
Notch
*d
Do not install SST (Claw Set)
Set 4 SST (claw set) to the fuel pump gauge retainer.
09808-14031
09808-01080
09808-01090
09808-01100
Note:Align the notch of SST (claw set) with the protrusion of the fuel pump gauge retainer.
Do not install SST (claw set) to the start of threads location of the fuel pump gauge retainer.
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*1
Fuel Pump Gauge Retainer
*a
SST (Claw Set)
*b
Hook
Push
SST (Bolt)
Push SST (claw set) against the fuel pump gauge retainer and tighten SST (bolt).
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*a
SST (Plate)
*b
SST (Claw Set)
SST (Bolt)
Temporarily install SST (plate) to SST (claw set) with 4 SST (bolt).
09808-14031
09808-01030
09808-01090
-
*a
Center Point of Fuel Pump Gauge Retainer
*b
SST (Plate)
Front
Adjust the position of SST (claw set) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.
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*1
Fuel Pump Gauge Retainer
*a
SST (Plate)
*b
SST (Claw Set)
*c
SST (Bolt)
Press
Press SST (claw set) against the rib of the fuel pump gauge retainer and tighten SST (bolt).
Install SST (handle) to SST (plate).
09808-14031
09808-01010
09808-01020
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-
*a
SST (Plate)
*b
SST (Handle)
Loosen
Slowly loosen the fuel pump gauge retainer by approximately 90°.
Note:Do not spin SST too fast or use an impact wrench as this may result in damage to components.
While one person loosens the fuel pump gauge retainer, have another person press down the rising fuel suction tube with pump and gauge assembly, securely insert the protrusion of the fuel suction tube with pump and gauge assembly into the groove of the fuel tank assembly, and then remove the fuel pump gauge retainer while making sure that the fuel suction tube with pump and gauge assembly is properly aligned.
*a
SST (Plate)
*b
SST (Handle)
*c
One Person in Charge of Loosening
*d
One Person in Charge of Pressing Down
*e
Paint Mark
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-
Note:The fuel suction tube with pump and gauge assembly 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 suction tube with pump and gauge assembly to rise up.
If the fuel pump gauge retainer is turned while the fuel suction tube with pump and gauge assembly and fuel tank assembly are not correctly aligned, the fuel suction tube with pump and gauge assembly will move with the fuel pump gauge retainer, and the fuel suction tube with pump and gauge assembly and fuel tank assembly may both be damaged.
Do not turn the fuel pump gauge retainer if the paint marks become misaligned.
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REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY
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.
-
*1
Fuel Suction Tube Set Gasket
Remove the fuel suction tube set gasket from the fuel tank assembly.
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*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
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.