FUEL PUMP REMOVAL
CAUTION / NOTICE / HINT
If a malfunction such as pump lock occurs and the fuel pump is damaged, excessive current may be continuously applied to the fuel pump control ECU assembly, damaging its internal parts. Make sure to replace the fuel pump control ECU assembly at the same time when replacing the fuel pump.
Perform "Inspection After Repair" after replacing the fuel pump.
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
for Sedan:
except Sedan:
REMOVE REAR FLOOR SERVICE HOLE COVER
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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
Remove the tube joint clip, and pull out the fuel tube joint of the fuel tank main tube sub-assembly.
*A
for Sedan
*B
except Sedan
*1
Tube Joint Clip
*2
Fuel Suction Plate Sub-assembly
*a
Fuel Tube Joint
*b
O-ring
*c
Nylon Tube
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-
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.
DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY
-
*A
for Sedan
*B
except Sedan
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
*A
for Sedan
*B
except Sedan
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
-
*A
for Sedan
*B
except Sedan
*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 tube joints of the fuel suction tube assembly with vinyl tape and then clean any dirt and foreign matter in order to prevent contamination of the fuel system.
Install SST to the fuel pump gauge retainer.
Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.
*A
for Sedan
*B
except Sedan
*1
Fuel Pump Gauge Retainer
-
-
*a
SST (Claw)
*b
Narrow
*c
Wide
*d
Correct
*e
Incorrect
-
-
09808-14030
09808-01030
09808-01040
09808-01050
Note:Install SST (claw) to the correct location.
Do not install SST (claw) to a location where the pitch between ribs of the fuel pump gauge retainer is narrow. (except Sedan)
-
*A
for Sedan
*B
except Sedan
*a
Center Point of Fuel Pump Gauge Retainer
Adjust the position of SST (claw) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.
Press SST (claw) against the rib of the fuel pump gauge retainer and tighten SST (bolt).
Install SST (handle).
Note:The torque required to remove the fuel pump gauge retainer may be as high as 200 N*m (2039 kgf*cm, 148 ft.*lbf) due to swelling of the fuel tank assembly, so perform the procedure with 2 people.
-
*a
Hold Down
*b
Pull
While holding down on the center of SST (handle) to prevent SST from separating from the fuel pump gauge retainer, pull SST (handle) with another person pulling the opposite end of SST (handle), and slowly loosen the fuel pump gauge retainer by approximately 90°.
09808-14030
09808-01010
09808-01020
09808-01030
09808-01040
09808-01050
Note:Be careful not to apply excessive downward force to SST, as this may damage the fuel pump or fuel tank assembly.
Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so be sure SST is horizontal when turning.
To prevent damage to parts, do not turn SST too vigorously.
If SST slips off of the fuel pump gauge retainer, loosen SST (bolt) and install SST again.
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*a
One Person in Charge of Loosening
*b
One Person in Charge of Holding
Continue to slowly loosen the fuel pump gauge retainer while another person is pressing down on the fuel pump to keep the protrusion of the fuel pump engaged with the groove of the fuel tank assembly so that the fuel pump does not move out of position.
Note:The fuel pump 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 pump to rise up.
If the fuel pump gauge retainer is turned while the fuel pump and fuel tank assembly are not correctly aligned, the fuel pump will move with the fuel pump gauge retainer, and the fuel pump and fuel tank assembly may both be damaged.
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.
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*1
Fuel Suction Tube Set Gasket
Remove the fuel suction tube set gasket from the fuel tank assembly.
Copy the fully tightened mark and start of threads mark of the fuel tank assembly.
-
*A
for Sedan
*B
except Sedan
*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
*e
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.
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