Fuel Pump: Locations

Removal

WARNING: Before starting the procedure, be sure to observe Precautions on Fuel System Service.

1) Relieve fuel pressure in fuel feed line.Fuel Pressure Release
2) Disconnect negative cable at battery.
3) Remove fuel filler cap.





4) Insert hose of a hand operated pump into fuel filler hose (1) and drain fuel in space "A" in the figure.

CAUTION: Do not force pump hose into fuel tank, or pump hose may damage fuel tank inlet valve (2).

5) Hoist vehicle.
6) Remove muffler.
7) Remove propeller shaft No. 2.





8) Remove EVAP canister with its bracket (1) from vehicle.





9) Disconnect fuel filler hose (1) and breather hose (2) from filler neck (3), then disconnect filter inlet hose (4) from canister air suction filter (5).
10) Due to absence of fuel tank drain plug, drain fuel tank by pumping fuel out through fuel tank filler. Use hand operated pump device to drain fuel tank.

CAUTION:
^ Do not force pump hose into fuel tank, or pump hose may damage fuel tank inlet valve.
^ Never drain or store fuel in an open container due to possibility of fire or explosion.

11) Disconnect fuel pipe joints from fuel pipes.
For quick joint, disconnect it as follows:
a) Remove mud, dust and/or foreign material between pipe and joint by blowing compressed air.





b) Unlock joint (1) lock by inserting special tool between pipe (2) and joint (1).
Special Tool
(A): 09919-47020
c) Disconnect joint from pipe.

WARNING: A small amount of fuel may be released after the fuel hose is disconnected. In order to reduce the chance of personal injury, cover the hose and pipe to be disconnected with a shop cloth. Be sure to put that cloth in an approved container when disconnection is completed.





12) Support fuel tank (1) with jack (2) and remove its mounting bolts.





13) Lower fuel tank a little to disconnect fuel pump connector (1), tank pressure and temperature sensor connector (2) and ground wire harness, then remove fuel tank.

Installation
1) If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.
2) Raise fuel tank (1) with jack and connect fuel pump connector, tank pressure and temperature sensor connector and ground wire harness and then clamp wire harness.





3) Install fuel tank to vehicle.
Tightening torque
Fuel tank bolt (a): 50 Nm (5.0 kgf-cm, 36.5 ft. lbs.)





4) Connect fuel filler hose (1), breather hose (2) and filter inlet hose (3) as shown in figure and clamp them securely.
Tightening torque
Fuel filler hose clamp (a): 3.5 Nm (0.35 kgf-cm, 2.5 ft. lbs.)





5) Connect fuel feed pipe (1), fuel return pipe (3) and purge pipe (2) to each pipe as shown in figure and clamp them securely.

CAUTION:
^ When connecting joint, clean outside surfaces of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.
^ Never let the fuel hoses touch the ABS sensor harness (if equipped).





6) Install EVAP canister with its bracket (1) to vehicle.
7) Install propeller shaft No. 2.
8) Install muffler.
9) Connect negative cable at battery. With engine OFF, turn ignition switch to ON position and check for fuel leaks.

Fuel Tank Inspection
After removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage. Also check fuel pump assembly gaskets for leaks, visually inspect fuel tank for leaks and damage. Replace any damaged or malconditioned parts.