1 of 12 8/18/ :52 AM
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1 1 of 12 8/18/ :52 AM REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE a. Discharge fuel system pressure. 2. REMOVE DECK BOARD SUB-ASSEMBLY a. Disengage the 5 clips and turn up the front side of the deck board. 3. REMOVE REAR SEAT TRACK BRACKET COVER OUTER 4. REMOVE REAR SEAT ASSEMBLY RH 5. REMOVE REAR SEAT ASSEMBLY LH 6. REMOVE REAR DOOR SCUFF PLATE LH 7. REMOVE REAR FLOOR SERVICE HOLE COVER a. Remove the rear floor service hole cover. b. Disconnect the fuel pump & sender gauge connector. 8. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
2 2 of 12 8/18/ :52 AM a. Disconnect the fuel pump tube. 1. Remove the tube joint clip, and pull out the fuel pump tube. NOTE: - 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 connector. - If mud or dirt gets in the connector, the O-rings may not seal properly. - Only disconnect the quick connector by hand. - 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 the pipe carefully.
3 3 of 12 8/18/ :52 AM b. Using SST, loosen the fuel pump gauge retainer. SST ( , , ) NOTE: - Loosen the retainer by turning it counterclockwise while holding the SST down. - Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank. HINT: A rib on the fuel pump gauge retainer can be fitted into a tip of the SST. c. Remove the fuel pump gauge retainer. d. Remove the fuel suction tube. NOTE: Be careful not to bend the arm of the fuel sender gauge. e. Remove the gasket from the fuel tank. 9. REMOVE FUEL SENDER GAUGE ASSEMBLY
4 4 of 12 8/18/ :52 AM a. Disconnect the fuel sender gauge connector [A]. b. Unlock the fuel sender gauge and slide it to remove. 10. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY a. Using a screwdriver with its tip wrapped in tape, disconnect the 4 snap-claws from the claw holes and remove the fuel suction plate. NOTE: Do not damage the fuel suction plate or fuel suction support No REMOVE FUEL PUMP ASSEMBLY
![5 of 12 8/18/2016 11:52 AM a. Disconnect the fuel pump connector [A]. b. Using a screwdriver with its tip wrapped in tape, disconnect the 2 snap-claws from the claw holes and pull out the fuel pump.](/docs-images/89/100995818/images/5-0.jpg "NOTE: Do not damage the fuel pump or fuel suction plate. c. Remove the O-ring and fuel pump spacer from the fuel pump. 12. REMOVE FUEL PUMP FILTER a. Using a screwdriver, pry out the clip. b.")
5 5 of 12 8/18/ :52 AM a. Disconnect the fuel pump connector [A]. b. Using a screwdriver with its tip wrapped in tape, disconnect the 2 snap-claws from the claw holes and pull out the fuel pump. NOTE: Do not damage the fuel pump or fuel suction plate. c. Remove the O-ring and fuel pump spacer from the fuel pump. 12. REMOVE FUEL PUMP FILTER a. Using a screwdriver, pry out the clip. b. Remove the fuel filter from the fuel pump. 13. REMOVE FUEL TUBE JOINT NO. 1
6 6 of 12 8/18/ :52 AM a. Disconnect the connector [A]. b. Using a screwdriver with the its wrapped in tape, disconnect the snap-claw from the claw hole and pull out the fuel tube joint. NOTE: Do not damage the fuel tube joint or fuel suction plate. 14. REMOVE FUEL PUMP HARNESS a. Remove the harness from the fuel tube joint No REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
7 7 of 12 8/18/ :52 AM a. Remove the clip. b. Pull out the pressure regulator from the fuel tube joint No. 1. c. Remove the 2 O-rings from the fuel tube joint No. 1. INSTALLATION 1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY a. Apply a light coat of gasoline or spindle oil to 2 new O-rings, and install them to the fuel pressure regulator. b. Apply a light coat of gasoline or spindle oil to the 2 O-rings again, and install the fuel pressure regulator to the fuel tube joint No. 1. c. Install the clip. 2. INSTALL FUEL PUMP HARNESS 3. INSTALL FUEL TUBE JOINT NO. 1
8 8 of 12 8/18/ :52 AM a. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel tube joint No. 1. b. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel tube joint No. 1 to the fuel suction plate. c. Connect the connector. 4. INSTALL FUEL PUMP FILTER a. Install the fuel pump filter with a new clip. 5. INSTALL FUEL PUMP ASSEMBLY a. Install the fuel pump spacer to the fuel pump. b. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel pump. c. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel pump to the fuel suction plate. d. Connect the fuel pump connector. 6. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
9 9 of 12 8/18/ :52 AM a. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel tube joint No. 1. b. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel suction plate to the fuel suction support No INSTALL FUEL SENDER GAUGE ASSEMBLY 8. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE a. Install a new gasket to the fuel tank. b. Attach the fuel suction tube to the fuel tank. NOTE: Be careful not to bend the arm of the fuel sender gauge. c. Align the keyway of the fuel suction tube support with the key of the fuel suction tube. d. Apply MP grease to the entire interior surface of the fuel pump gauge retainer.
10 10 of 12 8/18/ :52 AM e. Align the triangle mark on a new fuel pump gauge retainer with the "S" mark on the fuel tank while pushing down the fuel suction tube, and attach the fuel pump gauge retainer. f. Rotate the fuel pump gauge retainer by hand, then tighten it one complete turn and half using SST. The triangle mark on the fuel pump gauge retainer must be positioned between the "A" and "MAX." indications on the fuel tank. NOTE: Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
11 11 of 12 8/18/ :52 AM HINT: A rib on the fuel pump gauge retainer can be fitted into a tip of the SST. g. Connect the fuel pump tube. 1. Install the fuel pump tube and the tube joint clip. NOTE: - Check that there are no scratches or foreign objects on the connecting part. - Check that the fuel tube joint is inserted securely. - Check that the tube joint clip is on the collar of the fuel tube joint. - After installing the tube joint clip, check that the fuel tube joint has not been pulled off. 9. INSPECT FOR FUEL LEAK a. Check for fuel leaks. 10. INSTALL REAR FLOOR SERVICE HOLE COVER a. Install a new butyl tape to the rear floor service hole cover. b. Connect the fuel pump & sender gauge connector. c. Install the rear floor service hole cover. 11. INSTALL REAR DOOR SCUFF PLATE LH 12. INSTALL REAR SEAT ASSEMBLY LH 13. INSTALL REAR SEAT ASSEMBLY RH 14. INSTALL REAR SEAT TRACK BRACKET COVER OUTER
12 12 of 12 8/18/ :52 AM 15. INSTALL DECK BOARD SUB-ASSEMBLY 2016 ALLDATA, LLC. All Rights Reserved. (Version )
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