FUEL PUMP REMOVAL

CAUTION / NOTICE / HINT

Tip:

  • 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.

    Click hereClick here

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. REMOVE REAR SEAT CUSHION ASSEMBLY

    Click here

  3. REMOVE REAR FLOOR SERVICE HOLE COVER

    1. A296020

      Disconnect the 2 connectors.

    2. A354405

      Remove the rear floor service hole cover and butyl tape.

    3. Disconnect the fuel pump connector.

  4. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

    Click hereClick hereClick here

  6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A290614C04

      *1

      Tube Joint Clip

      *2

      Fuel Suction Plate Sub-assembly

      *3

      Fuel Tank Main Tube Sub-assembly

      *a

      Fuel Tube Joint

      *b

      O-ring

      *c

      Nylon Tube
      V100135

      Pull off
      V100136

      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.

      • 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.

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

    1. A354411

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

  8. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE

    A354412

    1. Disconnect the No. 1 charcoal canister outlet hose from the fuel suction tube with pump and gauge assembly.

  9. DISCONNECT NO. 2 FUEL TANK EVAPORATION TUBE

    1. A354413C01

      *a

      Retainer

      Release the retainer and disconnect the No. 2 fuel tank evaporation tube from the fuel suction tube with pump and gauge assembly.

  10. 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. A395658C01

      *a

      Paint Mark
      V100135

      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.

    2. Install SST to the fuel pump gauge retainer.

      1. A381180C02

        *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.

      2. A381172C02

        *1

        Fuel Pump Gauge Retainer

        *a

        SST (Claw Set)

        *b

        Hook
        V100135

        Push
        V100136

        SST (Bolt)

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

      3. A387114C01

        *a

        SST (Plate)

        *b

        SST (Claw Set)
        V100135

        SST (Bolt)

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

        09808-14031

        09808-01030

        09808-01090

      4. A395659C01

        *a

        Center Point of Fuel Pump Gauge Retainer

        *b

        SST (Plate)
        V100135

        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. A396896C01

        *1

        Fuel Pump Gauge Retainer

        *a

        SST (Plate)

        *b

        SST (Claw Set)

        *c

        SST (Bolt)
        V100135

        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).

        09808-14031

        09808-01010

        09808-01020

    3. A387117C01

      *a

      SST (Plate)

      *b

      SST (Handle)
      V100135

      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.

    4. 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.

      A395660C01

      *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.

  11. 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. A171478C01

      *1

      Fuel Suction Tube Set Gasket

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

    3. A354416C02

      *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
      V100135

      Front

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