Fuel Pump Replacement
Fuel Pump ReplacementCAUTION:
^ DO NOT spill fuel in the interior of the vehicle.
^ Use appropriate covers to protect upholstery, carpeting, etc when performing this procedure.
1. Turn the ignition ON and check the fuel level on the fuel gauge.
^ Make sure the full level in the fuel tank is 3/4 or less before starting this procedure.
WARNING:
If the fuel level is above 3/4, fuel will spill from the tank when the fuel pump is removed.
2. Write down the radio station presets.
3. Write down / record the customer settings for the following items (refer to the Service Manual as needed):
^ ATC (A/C system) Temperature Setting Trimmer, Foot Position Setting Trimmer, and Inlet Port Memory Function.
4. Release fuel pressure from the fuel lines using C-III.
a. Connect C-III to the vehicle.
b. Turn the ignition ON.
c. Perform FUEL PRESSURE RELEASE in ENGINE WORK SUPPORT mode.
d. Start the engine.
e. After the engine stalls, crank it two or three times to release all the fuel pressure.
f. Turn the ignition OFF.
g. Disconnect C-III from the vehicle.
5. Make sure the ignition is OFF.
6. Disconnect the negative battery cable.
7. Disconnect the fuel pump electrical connector.
8. Disconnect the fuel hose.
^ 1st, push in the taps on the sides of the connector.
^ 2nd, pull hose off.
NOTE:
^ A small amount of fuel may spill from the fuel line.
^ Have an absorbent cloth ready to soak up any spilled fuel.
IMPORTANT
NOTE:
To keep the fuel hose clean and to avoid damage and foreign materials, cover the end completely with a plastic bag or something similar.
9. Make sure you have a bucket or other suitable container available to hold the fuel pump when it is removed from the tank.
10. Remove the fuel pump assembly as follows:
a. Remove the retaining ring bolts.
b. Remove the retaining ring.
c. Lift the fuel pump part way out of the tank.
d. Disconnect the fuel transfer hose.
^ 1st, push in the taps on the sides of the connector.
^ 2nd, pull hose off.
11. Completely remove the fuel pump from the tank and put it in the bucket / container, then remove the bucket / container with the fuel pump from the vehicle.
NOTE:
Make the old fuel pump unusable by cutting off the fuel outlet tube.
IMPORTANT
12. Remove the old O-ring (see Figure 9).
^ Cut the old O-ring so it can't be reused.
13. Install a new O-ring.
14. Install the new fuel pump in the tank and secure the fuel transfer hose as follows:
a. Put the fuel pump partially in the tank.
CAUTION:
Don't bend the float arm during installation.
b. Push the transfer hose onto the pump until you hear/feel a positive SNAP/CLICK.
c. Pull back on the hose to confirm it is snapped / secured in place.
d. Lower the pump completely into the fuel tank.
e. Push the pump all the way in and make sure the tabs at the front and rear of the pump align with the holes in the fuel tank.
f. Install the fuel pump retainer so that its "flat spots" are parallel with the "flat spots" on the fuel tank.
g. Install the retainer bolts.
^ Torque: 2.3 Nm (0.23 Kg-m, 20 in lb)
15. Re-connect fuel feed hose:
a. Push the hose on the pump until you hear/feel a positive SNAP/CLICK.
b. Pull back on the hose to confirm it is snapped / secured in place.
16. Re-connect fuel pump electrical connector.
17. Connect the negative battery cable.
18. Check for fuel leaks:
a. Turn the ignition ON (with engine OFF).
b. Check for any fuel leaks at the fuel pump.
c. Start the engine.
d. Again - check for fuel leaks at the fuel pump.
19. Install the fuel pump cover and secure the 1/4 - turn clips.
20. Re-install / reposition the floor insulation.
21. Re-install the seat cushion and make sure routing and placement of seat buckles and belts is correct. (see Figure 16).
22. Reset the clock and the radio station presets.
23. Refer to the Service Manual for the following "reset / relearn" procedures:
^ Power Window Initialization
^ ATC Temperature Setting Trimmer (A/C system)
^ ATC Foot Position Setting Trimmer (A/C system)
^ ATC Inlet Port Memory Function (A/C system)
^ Rear View Monitor / Around View Monitor Predicted Course Line Center Position Adjustment (if equipped)
24. Inform the customer they will need to "reset" their Automatic Drive Positioner.