FUEL PUMP AND GAUGE ASSEMBLY REPLACEMENT <4N1>


1.Remove the second seat assembly (Refer to GROUP 52A - Second seat assembly ).

2.Remove the floor inspection lid (LH).

3.Disconnect the fuel pump and gauge assembly connector.
4.Release the fuel pressure in the fuel line (Refer to GROUP 13D - On-vehicle Service, Reduce Pressurized Fuel Lines ).

5.Insert a flat-tip screwdriver (6 mm wide and 1 mm thick) into the retainer of the fuel main pipe connector and fuel return pipe connector.

6.
caution When pushing up the retainer of the fuel main pipe connector and fuel return pipe connector, pay attention to avoid damage to the retainer.
Turn the flat-tip screwdriver inserted into the retainer by 90 degrees to push up the retainer and unlock the fuel main pipe connector and fuel return pipe connector.
7.Disconnect the fuel main pipe and fuel return pipe from the fuel pump and gauge assembly.

8.Remove the mounting nuts of fuel pump and gauge assembly.
9.Remove the fuel tank bracket and connector housing assembly and the fuel pump bracket plate.
10.
caution Pay attention not to damage the fuel gauge unit and float of the fuel pump and gauge assembly when removing the fuel pump and gauge assembly from the fuel tank.
Remove the fuel pump and gauge assembly from service hole <2WD>.

11.
caution Pay attention not to damage the fuel gauge unit and float of the fuel pump and gauge assembly when removing the fuel pump and gauge assembly from the fuel tank.
While removing the fuel pump and gauge assembly from service hole, disconnect the suction hose, and remove the fuel pump and gauge assembly from service hole completely <4WD>.
12.Replace the fuel pump and gauge assembly gasket with a new one.
13.
caution
  • Pay attention not to damage the fuel gauge unit and the float of the fuel pump and gauge assembly when installing it to the fuel tank.
  • When installing the fuel pump and gauge assembly to the fuel tank, check that the fuel gauge unit moving area moves smoothly.
Install the fuel pump and gauge assembly to the fuel tank through the service hole <2WD>.
14.
caution
  • When installing the fuel pump and gauge assembly into the fuel tank from the service hole, be careful not to damage the gauge unit and the float. In addition, be careful that the float does not catch the suction hose in the fuel tank.
  • When installing the fuel pump and gauge assembly to the fuel tank, check that the fuel gauge unit moving area moves smoothly.
While inserting the fuel pump and gauge assembly from the service hole to fuel tank, connect the suction hose and install the fuel pump and gauge assembly in the fuel tank <4WD>.
15.Install the fuel pump bracket plate and the fuel tank bracket and connector housing assembly.
16.Tighten the fuel pump and gauge assembly mounting nuts to the specified torque.
Tightening torque: 2.5 ± 0.4 N·m

17.Pull up the retainer of fuel main pipe and fuel return pipe to unlock before installing.

18.
caution
  • When pushing in the retainer of the fuel main pipe connector and fuel return pipe connector, pay attention to avoid damage to the retainer.
  • After the installation of the fuel main pipe connector and fuel return pipe connector, slightly pull the fuel main pipe and fuel return pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm play.
Install the fuel main pipe and fuel return pipe to the fuel pump and gauge assembly securely and push in the retainer of the fuel main pipe connector and fuel return pipe connector to lock the fuel main pipe and fuel return pipe and fuel pump and gauge assembly.
19.Connect the fuel pump and gauge assembly connector.
20.Install the floor inspection lid (LH).
21.Install the second seat assembly (Refer to GROUP 52A - Second seat assembly ).