FUEL PUMP UNIT REMOVAL/INSTALLATION[L3]

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Warning

•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”.

•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. 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.

Caution

•  Because the fuel tank is constructed such that the fuel level is higher than the installation surface of the fuel pump, fuel leakage could occur. If the fuel gauge indicates a fuel level of half or more, perform the following Steps 1-8 to drain approx. 10 L {11 US gal, 8.8 lmp gal} of fuel.

•  Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

•  To prevent the SST from coming off the fuel pump cap while performing the work, always perform the removal/installation procedure with 2 people. One person presses the SST against the cap from directly above, while the other person rotates the SST.

•  If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION[L3].)

2.  Lift the rear seat cushion (LH).

3.  Remove the scuff plate and turn over the carpet.

4.  Remove the service hole cover.

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5.  Disconnect the quick release connector as shown in the figure.

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6.  Connect a hose to the fuel pump unit.

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7.  Drain the fuel into a container used for collecting gasoline.

8.  Start the fuel pump using the following procedure.

Using M-MDS

1.  Connect the M-MDS to the DLC-2.

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2.  Using the simulation function “FP”, start the fuel pump.

Without using M-MDS

1.  Disconnect the negative battery cable.

2.  Remove the fuel pump relay.

Caution

•  Short the specified terminals because shorting the wrong terminal of the main fuse block may cause malfunctions.

3.  Using a jumper wire, short fuel pump relay terminals A and E in the main fuse block.

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4.  Connect the negative battery cable and operate the fuel pump.

Caution

•  The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

9.  Disconnect the negative battery cable.

10.  Remove in the order indicated in the figure.

11.  Install in the reverse order of removal.

12.  Inspect all parts by performing AFTER SERVICE PRECAUTION. (See AFTER REPAIR PROCEDURE[L3].)

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1	Fuel pump unit connector
2	Fuel pump cap (See Fuel Pump Cap Removal Note.) (See Fuel Pump Cap Installation Note.)
3	Fuel pump unit

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 install the SST without any gaps.

1.  Remove the fuel pump cap using the SST.

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Fuel Pump Cap Installation Note

Note

•  If the gasket is stained with fuel, the fuel pump unit cannot be aligned at the specified position, when tightening the cap. Make sure that the gasket is free of fuel.

1.  Align the fuel tank and fuel pump unit alignment marks as shown in the figure.

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2.  Install the SST as shown in the figure.

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3.  Using the SST, tighten the fuel pump cap with the specified tightening torque without shifting the alignment marks.

•  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.