Removal and Replacement
FUEL PUMP UNIT REMOVAL/INSTALLATION [LF, L3]
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".
NOTE:
- Gasket must be replaced anytime fuel pump is removed or replaced.
California Emission Regulation Applicable Model
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. Before Service Precaution
2. Disconnect the negative battery cable.
3. Remove the fuel tank. Service and Repair
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". After Service Precaution
Retainer ring removal note
1. Remove the retainer ring by tapping a retainer ring projection using a flathead screwdriver as shown in the figure.
Fuel pump unit removal note
NOTE:
- The fuel pump unit is secured by the two retainer clips with the bracket on the bottom surface of the fuel tank.
1. Using a fiber stick, disengage the retainer clips until the pump can be removed.
2. Remove the fuel pump gauge connection area from the fuel pump unit.
3. Set the fuel pump gauge out of the way and remove the fuel pump unit from the fuel tank.
Fuel pump unit installation note
NOTE:
- Keep the fuel pump gauge set out of the way.
1. Insert the fuel pump unit to the fuel tank.
2. Install the fuel pump gauge to the fuel pump unit.
3. Engage the retainer clips with the fuel pump unit.
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.
Except For California Emission Regulation Applicable Model
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. Before Service Precaution
2. Disconnect the negative battery cable.
3. Remove the fuel tank. Service and Repair
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". After Service Precaution
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.
Fuel pump cap installation note
WARNING:
- Make sure there is no foreign material on each of the parts. If there is foreign material on the parts, the fuel pump unit cannot be assembled correctly, which could result in fuel leakage.
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.
1. Replace the packing, fuel pump cap and the retainer with new parts.
CAUTION:
- New parts can deform depending on the temperature. If the parts deform, the fuel pump unit cannot be assembled correctly, which could result in fuel leakage. Therefore, keep new parts at room temperature for the specified period of time to stabilize the shape.
2. Leave new parts inside for the following period of time:
Stand-by time
- 12 h or more
3. Install a new retainer to the fuel tank.
a. Align the retainer tabs (3 locations) with the fuel tank grooves.
b. Verify that the tabs are inserted into the grooves and the retainer is installed correctly.
c. Verify the retainer is not damaged.
4. Install a new packing to the fuel tank.
a. Verify the packing groove is clean and free of foreign material.
b. Install the packing to the fuel tank so that it is inserted into the fuel tank grooves.
CAUTION:
- Install the fuel pump unit to the fuel tank being careful not to bend the fuel sender unit arm. If the arm is bent, the fuel sender unit will not operate correctly.
5. Install the fuel pump unit to the fuel tank.
a. Align the fuel pump unit alignment mark and the floating line on the fuel tank.
b. Verify the tab on the fuel pump unit flange with the notch on the retainer.
6. Set on a new fuel pump cap.
a. Apply downward force (push down) on the center of the fuel pump unit flange.
NOTE:
- Align the fuel pump cap with the tightening start position of the retainer and tighten the fuel pump cap with the start position as 0 °.
- The fuel pump cap tightening start position is the position where the spaces between the ribs become narrow. The retainer tightening start position is the notch position.
b. Align the tightening start position on the fuel pump cap and the tightening start point of the retainer.
WARNING:
- No grease or lubrication allowed on parts during installation. Parts could slide or they cannot be tightened to the specified torque. As a result, fuel leakage could occur.
- When tightening the fuel pump cap, be careful that the points indicated below have not deviated. If there is deviation, the fuel pump unit cannot be installed correctly, which could result in fuel leakage.
- The fuel pump unit alignment mark and the floating line on the fuel tank
- The fuel pump unit nipple and the retainer gap
7. Tighten the fuel pump cap.
a. Tighten the fuel pump cap by hand to the specified angle or more until the flange is fixed.
Fuel pump cap rotation angle
- 270 ° or more
b. Verify that the fuel pump cap is tightened correctly.
i. The gap between the bottom of the fuel pump cap and the tank surface is even all around.
- If the fuel pump cap is not tightened uniformly, loosen it by hand and re-install it.
c. Install the SST.
NOTE:
- The fuel pump cap rotation angle is the angle from the 0 ° position. The angle tightened to using the SST includes the angle tightened by hand.
d. Tighten the fuel pump cap to the specified torque and to the specified angle or more.
Fuel pump cap rotation angle
- 620-680 °
Fuel pump cap tightening torque
- 110 Nm {12 kgf-m, 82 ft-lbf} or more
e. Verify that the fuel pump cap is tightened correctly.
i. The gap between the top of the fuel pump unit flange and the fuel pump cap is even all around.
- If it is not tightened uniformly, re-install it using the following procedure.
ii. The gap between the fuel pump unit and fuel tank is even all around.
- If it is not tightened uniformly, re-install it using the following procedure.
iii. Verify that the fuel pump unit alignment mark and the floating line on the fuel tank are aligned.
- If they are not aligned, re-install it using the following procedure.
iv. Verify that the fuel pump unit nipple and the retainer gap are aligned.
- If it is not aligned, re-install using the following procedure.
1Install the SST.
2Remove the fuel pump cap, fuel pump unit, packing, and retainer.
3Verify that the retainer is not damaged.
-If both of the retainer anti-rotation tabs are broken, replace it with new one.
1Return to Step 2 and re-install.