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 notices before proceeding with work Click here.

  2. REMOVE REAR NO. 1 SEAT ASSEMBLY (for Side)

    Click here

  3. REMOVE REAR NO. 1 SEAT ASSEMBLY (for Center)

    Click here

  4. REMOVE REAR NO. 2 SEAT ASSEMBLY

    Click here

  5. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. B005YFZ

      Using a clip remover, remove the 2 clips.

    2. Turn over the front floor carpet.

    3. B005Z59

      Remove the rear floor service hole cover.

    4. B005Y8Q

      Disconnect the connector from the fuel suction tube assembly.

  6. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  7. REMOVE DECK BOARD ASSEMBLY

    Click here

  8. REMOVE NO. 1 DECK BOARD

    Click here

  9. REMOVE NO. 2 DECK BOARD

    Click here

  10. REMOVE REAR DECK FLOOR BOX

    Click here

  11. REMOVE DECK FLOOR BOX RH

    Click here

  12. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  13. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B005Z63E02
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tube Joint
      *3 O-ring

      Remove the tube joint clip, then pull the fuel tube joint out of the plug of the fuel suction tube with pump and gauge 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.

  14. DISCONNECT CHARCOAL CANISTER OUTLET HOSE


    1. B005Y89

      Disconnect the charcoal canister outlet hose from the fuel suction tube with pump and gauge assembly.

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


    1. B005XLH

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

  16. 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.


    1. B005ZJ4C02
      *a Fully Tightened Mark on Fuel Tank Assembly
      *b Start of Threads Mark on Fuel Tank Assembly
      *c Copy of Fully Tightened Mark
      *d Copy of Start of Threads Mark
      B005XEC Front

      Copy the start of threads mark and fully tightened marks from the fuel tank assembly to the vehicle body in order to record their locations.

    2. B005ZSIC02
      *a Paint Mark
      B005XEC 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 a protrusion that engages with a notch 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.

    3. Install SST to the fuel pump gauge retainer.


      1. B005ZBCC02
        *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.

        SST
        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.

      2. B005ZGJC02
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        B005XEC Push
        B005Y3Y SST (Bolt)

        Push SST (claw set) against the fuel pump gauge retainer and tighten SST (bolt).

      3. B005XZ0C02
        *a SST (Plate)
        *b SST (Claw Set)
        B005XEC SST (Bolt)

        Temporarily install SST (plate) to SST (claw set) with 4 SST (bolt).

        SST
        09808-14031   ( 09808-01030, 09808-01090 )
      4. B005Z3YC02
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        B005XEC 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.

      5. B005YHMC02
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        B005XEC Press

        Press SST (claw set) against the rib of the fuel pump gauge retainer and tighten SST (bolt).

      6. Install SST (handle) to SST (plate).

        SST
        09808-14031   ( 09808-01010, 09808-01020 )
    4. B005Y7NC02
      *a SST (Plate)
      *b SST (Handle)
      B005XEC 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.

    5. 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.

      B005Z8KC02
      *a SST (Plate) *b SST (Handle)
      *c One Person in Charge of Loosening *d One Person in Charge of Pressing Down
      *e Paint Mark - -

      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.

  17. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B005ZG1

      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. B005ZJXE01
      Text in Illustration
      *1 Fuel Suction Tube Set Gasket

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