Up to 08/2009

2GR-FE FUEL: FUEL PUMP: REMOVAL

1. PRECAUTION (w/ Navigation System for HDD)

NOTICE:
After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.

2. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Service Precautions.

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

4. REMOVE REAR SEAT ASSEMBLY LH

(a) Remove the rear seat assembly LH Removal.

5. REMOVE REAR DOOR SCUFF PLATE LH Removal

6. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH Removal

7. REMOVE REAR FLOOR SERVICE HOLE COVER

(a) Using a clip remover, remove the clip and lift up the front floor carpet.





(b) Remove the rear floor service hole cover.





(c) Disconnect the fuel pump connector.

8. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

(a) Remove the tube joint clip, and pull out the fuel tank main tube sub-assembly.





Text in Illustration





NOTICE:
* Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
* It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
* Disconnect the quick connector by hand. Do not use any tools.
* Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
* If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off carefully.
(b) Using a 6 mm socket hexagon wrench, install SST to the fuel pump gauge retainer.





SST : 09808-14020

09808-01410

09808-01420

09808-01430

HINT
* Engage the SST claws securely with the fuel pump gauge retainer ribs to secure SST.
* Install SST while pressing the SST claws toward the fuel pump gauge retainer (toward the center of SST).
(c) Using SST, loosen the fuel pump gauge retainer.





SST : 09808-14020

09808-01410

09808-01420

09808-01430

NOTICE:
* Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
* Loosen the retainer by turning it counterclockwise while holding SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank.
HINT
The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

(d) Remove the fuel pump gauge retainer.

(e) Remove the fuel suction tube with pump and gauge.





Text in Illustration





NOTICE:
Be careful not to bend the arm of the fuel sender gauge.

(f) Remove the gasket from the fuel tank.