RX400h · Service Manual ENGINE

REMOVAL

Removal / installation


1. DISCHARGE FUEL SYSTEM PRESSURE
(Click here)

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3. REMOVE EXHAUST PIPE ASSEMBLY CENTER
(Click here)

4. REMOVE FRONT FLOOR HEAT INSULATOR NO.3

  1. A107236
    Remove the 5 nuts and front floor heat insulator No.3.


5. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1

  1. A108198
    Disengage the 4 grommets.

  1. Remove the screw and fuel tank protector sub-assembly No.1.


6. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.3

  1. A107237
    Remove the nut and disconnect the parking brake cable assembly No.3.


7. DISCONNECT FUEL TANK WIRE

  1. A107240
    Separate the fuel tank wire connector from the bracket.

  1. Disconnect the connector.


8. REMOVE CHARCOAL CANISTER PROTECTOR

  1. A112347
    Remove the 3 bolts and charcoal canister protector.


9. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY

  1. A108183E01
    Disconnect the fuel tank to canister tube sub-assembly from the charcoal canister assembly.

    1. Pinch the tube connector and then pull out the fuel tank to canister tube sub-assembly.

      NOTICE:
      1. Check for dirt or other foreign objects around the connector before this operation. Clean the connector as necessary.
      2. Be careful not to allow mud or foreign matter to scratch or come into contact with the pipe and connector that are sealed by an O-ring.
      3. Do not use any tools for this operation.
      4. Do not damage the disconnected pipe and connector. Prevent intrusion of foreign objects by covering the pipe and connector with a plastic bag.
      5. When the pipe and connector are stuck, push and pull the connector to release. Pull out the connector carefully.

  1. A112348
    Separate the fuel tank to canister tube from the clamp.


10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

  1. A112343E01
    Pinch the tabs of the retainer to disengage the lock claws and pull the retainer down as shown in the illustration.

  1. Pull out the fuel tank main tube.

    NOTICE:
    1. Check for dirt or other foreign objects around the connector before this operation. Clean the connector as necessary.
    2. Be careful not to allow mud or foreign matter to scratch or come into contact with the pipe and connector that are sealed by O-rings.
    3. Do not use any tools for this operation.
    4. Do not damage the disconnected pipe and connector. Prevent intrusion of foreign objects by covering the pipe and connector with a plastic bag.
    5. When the pipe and connector are stuck, push and pull the connector to release. Pull out the connector carefully.


11. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

  1. A107241
    Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.

  1. Loosen the hose clamp bolt and disconnect the fuel tank breather hose.


12. REMOVE FUEL TANK ASSEMBLY

  1. A107242
    Set a transmission jack to the fuel tank.

  1. Remove the 4 bolts and the fuel tank bands.

  1. Operate the transmission jack, and remove the fuel tank.


13. REMOVE FUEL PUMP AND GAUGE WITH SUCTION TUBE

  1. A107243
    Disconnect the fuel pump connector.

  1. A112358E01
    Remove the tube joint clip and clamp, and pull out the fuel pump tube.

    NOTICE:
    1. Check that there is no dirt or foreign matter around the fuel tube joint. After cleaning off any dirt, proceed with the work.
    2. Be careful not to allow dirt or foreign matter to scratch or come into contact with the fuel tube connector and fuel suction plate that are sealed by O-rings.
    3. Do not use any tools for this work.
    4. Do not bend or twist the nylon tube by force.
    5. Cover the disconnected fuel tube joint with a plastic bag.
    6. When the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube with your fingers, and turn it carefully to release. Disconnect the fuel tank tube.

  1. A107245
    Remove the 8 bolts and fuel tank vent tube set plate.

  1. A112353
    Pull out the fuel pump assembly from the fuel tank.

    NOTICE:
    1. Do not damage the fuel pump filter.
    2. Be careful not to bend the arm of the sender gauge.

  1. Remove the gasket from the fuel suction tube.


14. REMOVE FUEL SENDER GAUGE ASSEMBLY

  1. A107253E01
    Disconnect the fuel sender gauge connector.

  1. Unlock the fuel sender gauge, then slide and remove it.


15. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY

  1. A107259E01
    Disconnect the fuel pump connector.

  1. Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws through the claw holes, and pull out the fuel suction plate.

    NOTICE:
    Do not damage the fuel suction support.


16. REMOVE FUEL PUMP HARNESS

  1. A107254E01
    Disconnect the connector.

  1. Using a screwdriver, pry out the fuel pump harness.


17. REMOVE FUEL SUCTION SUPPORT NO.2

  1. A112354
    Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws through the claw holes, and remove the fuel suction support.

    NOTICE:
    Do not damage the fuel suction support.


18. REMOVE FUEL PUMP CUSHION RUBBER

  1. A112355
    Remove the fuel pump cushion rubber from the fuel pump.


19. REMOVE FUEL PUMP AND FUEL FILTER ASSEMBLY

  1. A112356
    Pull out the fuel pump from the fuel tank fuel filter.


20. REMOVE FUEL PRESSURE WITH JET PUMP REGULATOR ASSEMBLY

  1. A107258
    Remove the fuel pressure with jet pump regulator assembly from the fuel tank fuel filter.

  1. A108182E01
    Remove the O-ring from the fuel pressure with jet pump regulator assembly.

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