FUEL PUMP UNIT REMOVAL/INSTALLATION [ZJ, ZY]

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Warning

•  Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”, while referring to “BEFORE SERVICE PRECAUTION”.

•  Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit removal/installation, always complete the “Fuel Leak Inspection After Fuel Pump Unit Installation”.

•  A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [ZJ, ZY].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY].)

3.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

4.  Remove the service hole cover.

5.  Remove in the order indicated in the table.

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1	Fuel pump unit connector
2	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [ZJ, ZY].)
3	Fuel pump cap (See Fuel Pump Cap Removal Note.) (See Fuel Pump Cap Installation Note.)
4	Fuel pump unit

6.  Install in the reverse order of removal.

7.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [ZJ, ZY].)

Fuel Pump Cap Removal Note

Caution

•  The fuel pump cap could be damaged if the SST is used with any gap between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

1.  Remove the fuel pump cap using the SST.

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Fuel Pump Cap Installation Note

Note

•  The fuel pump unit will rotate and cannot be secured in the specified position if there is any gasoline on the gasket. Thoroughly wipe away all gasoline from the gasket.

•  Make the markings to be easily visible when the fuel pump cap is installed.

•  Marks are provided on the fuel pump unit and fuel tank for correct installation of the fuel pump unit.

1.  Mark the fuel pump cap and the fuel tank at the point where the threading of each part begins as shown in the figure.

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2.  Align the fuel tank alignment mark with the fuel pump unit as shown in the figure.

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3.  Align the fuel tank and fuel pump cap markings.

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4.  Rotate the fuel pump cap counterclockwise until the cap marking is approx. 15° away from the fuel tank marking as shown in the figure.

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5.  While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 180 ° clockwise.

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Caution

•  The cap could be damaged if the SST is used with any play between the cap and the SST. Securely install the SST so that there is no gap between the SST tabs and the side of the cap.

6.  Set the SST as shown in the figure.

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Note

•  The total rotation angle is 450—495 °if the approx.180° from Step 5 is included.

7.  Using the SST, tighten the fuel pump cap within the specified rotation angle and cap tightening torque without shifting the fuel tank and fuel pump unit alignment marks.

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Note

•  The total rotation angle is 450—495 ° if the approx.180 ° from Step 5 is included.

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•  If the specified tightening torque cannot be obtained, replace the fuel pump cap and gasket.

•  If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and gasket, replace the fuel tank.