FUEL PUMP UNIT REMOVAL/INSTALLATION [L3]

Warning

• Fuel is hazardous. It can very easily ignite, causing death or serious injury and damage. Fuel can also irritate skin and eyes. To prevent this, always perform the 'Fuel Line Safety Procedure' referring to the BEFORE SERVICE PRECAUTION.

• Fuel is hazardous. It can very easily ignite, causing death or serious injury and damage. Fuel can also irritate skin and eyes. To prevent this, always perform the 'Fuel Leakage Inspection After Pump Unit Installation' for fuel pump unit removal/installation.

R.H.D. Model

1. Perform the 'Fuel Line Safety Procedure' referring to the BEFORE SERVICE PRECAUTION. (See BEFORE SERVICE PRECAUTION [L3].)

2. Disconnect the negative battery cable.

3. Lift up the rear seat cushion (LH).

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

5. Remove the service hole cover.

6. Remove in the order indicated in the figure.

7. Install in the reverse order of removal.

8. Inspect all parts by performing AFTER SERVICE PRECAUTION. (See AFTER SERVICE PRECAUTION [L3].)

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.

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.

2. Install the SST as shown in the figure.

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.

Fuel pump cap tightening torque

88.2-107.8 N·m {9.00-10.9 kgf·m, 65.1-79.5 ft·lbf}

Fuel leakage inspection after pump unit installation

1. Before installing the fuel tank, verify that there is no leakage when a pressure of +5.9 kPa {44 mmHg, 17 inHg} is applied to the fuel tank.

2. Install the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [L3].)

3. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed.

4. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the fuel pump unit.

L.H.D. Model

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [L3].)

2. Disconnect the negative battery cable.

3. Lift up the rear seat cushion (LH).

4. Remove the service hole cover.

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

7. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [L3].)

Retainer ring removal note

1. Remove the retainer ring by tapping a retainer ring projection using a flathead screwdriver as shown in the figure.

Retainer ring installation note

1. Tap a retainer ring projection using a flathead screwdriver as shown in the figure and tighten the retainer until it is fixed in place.