FUEL PUMP UNIT REMOVAL/INSTALLATION [L3 4WD]

Warning

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure".

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit removal/installation, always complete the "Fuel Leak Inspection After Fuel Pump Unit Installation".

• A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

Caution

• Because the fuel tank is constructed such that the fuel level is higher than the installation surface of the fuel pump, fuel leakage could occur. If the fuel gauge indicates a fuel level of half or more, perform the following Steps 1-6 to drain the fuel.

• Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

Note

• Since the fuel pump unit is integrated with the fuel filter, it needs to be replaced every 75,000 km.

1. Complete the "BEFORE REPAIR PROCEDURE". (See BEFORE REPAIR PROCEDURE [L8, LF, L3].)

2. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [L8, LF, L3].)

3. Disconnect the quick release connector connected to the fuel distributor.

4. Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.

5. Start the fuel pump using the following procedure.

1. Connect the WDS or equivalent to the DLC-2.

2. Using the simulation function "FP", start the fuel pump.

1. Short the check connector terminal F/P to body GND using a jumper wire.

2. Turn the ignition switch to ON position to operate the fuel pump.

Caution

• The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

Note

• If the fuel tank is full, drain approx. 40 L {10.6 US gal, 8.8 Imp gal} of fuel until the fuel gauge indicates approx. 3/8 of a tank.

6. When the fuel gauge needle indicates that the fuel level is half or less as shown in the figure, stop the fuel pump.

7. Disconnect the negative battery cable.

8. Complete the following in order to the work area.

(1) Loosen the bolt of the fuel tank strap.

(2) Lower the fuel tank to a position where the SST can be attached from the service hole cover.

9. Remove the rear seat cushion.

10. Remove in the order indicated in the table.

11. Install in the reverse order of removal.

12. Complete the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE [L8, LF, L3].)

13. Complete the "Fuel Leak Inspection After Fuel Pump Unit Installation". (See Fuel Leak Inspection After Fuel Pump Unit Installation.)

Plastic Fuel Hose Removal Note

Caution

• The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab over the stopper.

1. Disconnect the quick release connector.

(1) Push the tab on the locking coupler 90 degrees until it stops.

(2) Pull the fuel hose straight back.

Note

• The stopper may be removed from the quick connector. Take care not to lose it.

Reinstall it to the quick release connector before reconnecting the fuel line.

• The locking coupler has two internal locking tabs which retain the fuel pipe. Be sure that the tab on the locking coupler is rotated until it stops to release two internal locking tabs.

2. Cover the disconnected quick release connector and fuel pipe with vinyl sheets or the like to prevent them from being scratched or contaminated with foreign material.

Fuel Pump Cap Removal Note

1. Using the SST, remove the fuel pump cap.

Fuel Pump Cap Installation Note

1. Verify that the fuel tank mark is aligned with the fuel pump unit mark as shown.

2. Using the SST, tighten the fuel pump cap without shifting the mark.

80-90 N·m {8.2-9.1 kgf·m, 60-66 ft·lbf}

Plastic Fuel Hose Installation Note

Note

• A checker tab is integrated with quick release connector for new plastic fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe.

1. Inspect the fuel pump unit sealing surface for damage and deformation, and replace as necessary.

• If the quick release connector O-ring is damaged, replace the plastic fuel hose.

2. Slightly apply clean engine oil to the sealing surface of the fuel pump unit.

3. Align the fuel pipe on the fuel pump unit and quick release connector so that the tabs of the retainer are correctly fitted into the quick release connector. Push the quick release connector straight into the retainer until a click is heard.

4. Lightly pull and push the quick release connector a few times by hand and verify that it can move 2.0-3.0 mm {0.08-0.11 in} and it is connected securely.

• If quick release connector does not move at all, verify that O-ring is not damaged and slipped, and reconnect the quick release connector.

Fuel Leak Inspection After Fuel Pump Unit Installation

1. Drive the vehicle.

2. Perform a quick start and a hard brake 5-6 times.

3. Stop the vehicle.

4. Verify that there is no fuel leakage near the fuel pump unit in the vehicle interior.