Fuel pump ASSY (FA20)
Components Inspection Removal / installation
FUEL
FUEL PUMP ASSY (FA20)
EXPLODED VIEW
REMOVAL
CAUTION:
If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain the fuel before starting the work to avoid the fuel to spill.
1. Fuel spill prevention procedure (Refer to 
)
)2. Draining of fuel (method with SSM3)
(1) If the fuel gauge indicates that two thirds or more of the fuel is remaining, drain the fuel according to the following procedure.
CAUTION:
Be careful not to spill fuel.
NOTE:
·If the fuel pump cannot be driven, refer to the method for draining the fuel from the fuel tank to filler pipe hose.
·Be careful not to let the battery run-out.
·Be careful not to let the battery run-out.
(a) Put alignment marks on the fuel hoses on the port injection side and on the direct injection side.
Captions in illustration
| *a |
Alignment marks |
(b) Loose the hose clamp, disconnect the port injection side fuel hose and cylinder injection side fuel hose.
CAUTION:
·Before starting the work, remove the foreign matters such as dirt on the fuel hose connection.
·Be careful not to spill fuel.
·Catch the fuel from fuel hoses using a container.
·Be careful not to spill fuel.
·Catch the fuel from fuel hoses using a container.
(c) Put the end of the hose into a container.
(d) Drive the fuel pump and drain the fuel using the SSM3.
CAUTION:
Be careful not to spill fuel.
NOTE:
Always be sure to use a steel container and ground the container as gasoline can easily become charged with static electricity.
(e) Using the hose clamp, connect the fuel hose.
Standard value:
Standard value:
Tightening torque=1.3N·m
{
13kgf·cm}
{1.0ft·lbf}
3. Draining of fuel (method from fuel tank to filler pipe hose)
(1) If the fuel gauge indicates that two thirds or more of the fuel is remaining, drain the fuel according to the following procedure.
WARNING:
Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
CAUTION:
·Be careful not to spill fuel.
·Fuel may remain in the fuel filler pipe. Drain the fuel from the fuel filler pipe through the fill opening using a gasoline proof pump and gasoline proof hose with a diameter of 10 mm {0.3937 in} or less before starting the work.
·Fuel may remain in the fuel filler pipe. Drain the fuel from the fuel filler pipe through the fill opening using a gasoline proof pump and gasoline proof hose with a diameter of 10 mm {0.3937 in} or less before starting the work.
(a) Remove the exhaust pipe ASSY CTR. (Refer to )
)(b) Remove the exhaust tail pipe ASSY. (Refer to )
)
(c) Loosen the hose clamp and disconnect the fuel tank to filler pipe hose.
CAUTION:
·Before starting the work, remove the foreign matters such as dirt on the fuel tank to filler pipe hose connection.
·Be careful not to spill fuel.
·Be careful not to spill fuel.
(d) Set a metal container under the vehicle and drain the fuel from the fuel tank to filler pipe hose opening using the gasoline proof hose with a diameter of 10 mm {0.3937 in} or less.
CAUTION:
Be careful not to spill fuel.
NOTE:
Always be sure to use a steel container and ground the container as gasoline can easily become charged with static electricity.
(e) Install the fuel tank to filler pipe hose with the hose clamp.
Standard value:
Standard value:
Tightening torque=2.0N·m
{
20kgf·cm}
{1.5ft·lbf}
4. Disconnection of the battery ground terminal (Refer to )
)5. Removal of separate type rear seat cushion ASSY LH (Refer to )
)
6. Rear floor service hole cover NO.2 removal
(1) Push in the grommet to remove the rear floor service hole cover NO.2.
(2) Remove the butyl tape and remove the rear floor service hole cover NO.2.
(3) Disconnect the fuel pump connector.
7. Fuel pump ASSY removal
(1) Disconnect the fuel delivery tube. (Refer to )
)CAUTION:
Be careful not to spill fuel.
(a) Remove the fuel delivery pipe from the fuel tank.
(2) Ring nut removal
(a) Use the SST to loosen the ring nut.
SST
42099CA000
CAUTION:
·Do not use any tools other than the SST.
·Be careful not to damage the tube with the SST.
·Before setting the SST, move the tube to a position outside the SST.
·Be careful not to damage the tube with the SST.
·Before setting the SST, move the tube to a position outside the SST.
NOTE:
Insert the cutout portion of SST into the rib of ring nut to fix the SST securely.
(3) Remove the ring nut and ring nut plate while holding the fuel pump ASSY by hand.
(4) Disconnect the fuel sub delivery tube and remove the fuel pump ASSY from the fuel tank.
CAUTION:
·When disconnecting the fuel sub delivery tube, do not pull the tube strongly.
·Do not bend the arm of fuel sender gauge ASSY.
·Do not turn the fuel pump ASSY in the fuel tank to prevent the arm of fuel sender gauge ASSY from bending.
·Be careful not to spill the fuel remaining in the fuel pump ASSY outside the fuel tank or in the vehicle.
·Do not bend the arm of fuel sender gauge ASSY.
·Do not turn the fuel pump ASSY in the fuel tank to prevent the arm of fuel sender gauge ASSY from bending.
·Be careful not to spill the fuel remaining in the fuel pump ASSY outside the fuel tank or in the vehicle.
(5) Remove the gasket from the fuel tank.
DISASSEMBLY
CAUTION:
Do not disconnect the press fit hoses of fuel pump ASSY shown in the figure.
1. Fuel sender gauge ASSY removal (Refer to )
)
2. Fuel sub tank removal
(1) Disconnect the fuel pump harness connector.
(2) Hold down the fuel suction plate in the direction of arrow shown the figure.
(3) Remove the E-ring.
(4) Using a flat tip screwdriver wrapped with protective tape, release the claw and disconnect the jet pump nozzle.
Captions in illustration
| *1 |
Protective tape |
(5) Using a flat tip screwdriver wrapped with protective tape, release the three claws and pull out the fuel suction plate.
CAUTION:
Do not damage the fuel sub tank and fuel filter.
(6) Using a flat tip screwdriver wrapped with protective tape, release the claw and disconnect the jet pump.
(7) Remove the O-ring from the fuel sub tank.
3. Fuel pump removal
(1) Release the two claws using a flat tip screwdriver wrapped with protective tape.
(2) Using a flat tip screwdriver wrapped with protective tape, release the three claws and pull the fuel pump straight out.
CAUTION:
Do not damage the fuel pump and fuel filter.
(3) Disconnect the connector and remove the fuel pump harness.
ASSEMBLY
1. Fuel pressure regulator installation
2. Fuel pump installation
(1) Attach the spacer and a new O-ring to the fuel pump.
(2) Connect the connector and connect a new fuel pump harness.
Captions in illustration
| *1 |
Fuel pump harness |
| *2 |
O-ring |
| *3 |
Spacer |
(3) Apply a coat of gasoline to the O-ring and install the fuel pump to the fuel filter.
CAUTION:
Install it so that the O-ring is not cut or pinched.
3. Fuel sub tank installation
(1) Set the fuel suction plate on the fuel sub tank through the spring.
(2) Apply a coat of gasoline to a new O-ring and install it to the jet pump.
Captions in illustration
| *1 |
O-ring |
(3) Install the jet pump to the fuel sub tank.
CAUTION:
·Install it so that the O-ring is not cut or pinched.
·Be sure to engage the claw.
·Be sure to engage the claw.
(4) Engage the three claws and install the fuel filter to the fuel sub tank.
(5) Engage the claw and install the jet pump nozzle to the fuel sub tank.
(6) Install a new E-ring.
(7) Connect the fuel pump harness connector and install the harness to the four clamps.
4. Fuel sender gauge ASSY installation (Refer to )
)INSTALLATION
1. Fuel pump ASSY installation
(2) Connect the fuel sub delivery tube.
CAUTION:
·When connecting the fuel sub delivery tube, do not pull the tube strongly .
·Do not bend the arm of fuel sender gauge ASSY.
·Do not bend the arm of fuel sender gauge ASSY.
(3) Insert the fuel pump ASSY into the fuel tank and install the new gasket, which was installed to the fuel pump ASSY earlier, to the fuel tank.
CAUTION:
Improper installation such as warpage, slip, etc. results in fuel leakage. Make sure that there is no warpage, slip, etc. in the entire circumference when installing the gasket to the fuel tank.
(4) Apply gasoline to the gasket.
Captions in illustration
| *1 |
Gasket |
| *a |
Areas of gasoline application |
CAUTION:
·When applying gasoline to the gasket, apply it to the area as shown in the figure.
·Be careful that no gasoline comes into contact with the threaded portion of fuel tank.
·Make sure that there is no fuel, foreign matter, etc. on the sealing portion.
·Be careful that no gasoline comes into contact with the threaded portion of fuel tank.
·Make sure that there is no fuel, foreign matter, etc. on the sealing portion.
(5) Set the fuel pump ASSY in the installation position range mark of fuel tank.
Captions in illustration
| *a |
Installation position range mark |
(6) Install a new ring nut plate and ring nut, and then temporarily tighten the ring nut.
(7) Tighten the ring nut using the SST.
Standard value:
SST
42099CA000
Standard value:
Tightening torque=85N·m
{
867kgf·cm}
{62.7ft·lbf}
CAUTION:
·Do not use any tools other than the SST.
·Be careful not to damage the tube with the SST.
·Before setting the SST, move the tube to a position outside the SST.
·Make sure that the position mark on the fuel pump ASSY is located within the installation position range mark on the fuel tank as shown in the figure.
·After tightening to the specified torque, confirm the tightening by tightening it to the specified torque again.
·Be careful not to damage the tube with the SST.
·Before setting the SST, move the tube to a position outside the SST.
·Make sure that the position mark on the fuel pump ASSY is located within the installation position range mark on the fuel tank as shown in the figure.
·After tightening to the specified torque, confirm the tightening by tightening it to the specified torque again.
NOTE:
Insert the cutout portion of SST into the rib of ring nut to fix the SST securely.
(8) Connect the fuel delivery tube. (Refer to )
)(9) Install the fuel delivery tube to the fuel tank. (Refer to )
)(10) Connect the fuel pump connector.
2. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
3. Rear floor service hole cover NO.2 installation
(1) Install the rear floor service hole cover NO.2 using new butyl tape.
4. Separate type rear seat cushion ASSY LH installation (Refer to )
)UNIT INSPECTION
1. Fuel pump check
(1) Resistance check
(2) Operation check
(a) Apply the battery voltage between the terminals and check the motor operation.
CAUTION:
·Drain the fuel completely.
·Perform the check in a short period of time (10 sec. or less).
·Place the fuel pump as far apart as possible from the battery.
·Perform the check in a short period of time (10 sec. or less).
·Place the fuel pump as far apart as possible from the battery.