FUEL PUMP AND GAUGE ASSEMBLY REPLACEMENT <4B1-PHEV>


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

2.Remove the floor inspection lid (RH).

3.Disconnect the fuel pump and gauge assembly connector.
4.Release the fuel pressure in the fuel line (Refer to GROUP 13E - 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.

6.
caution When pushing up the retainer of the fuel main 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.

7.Remove the mounting nuts of fuel pump and gauge assembly.
8.Remove the fuel pump bracket plate.

9.
caution Pay attention not to damage the gauge unit and the float of fuel pump and gauge assembly when withdrawing it from the service hole.
While withdrawing the fuel pump and gauge assembly from the service hole, disconnect the suction hose from the fuel pump and gauge assembly to remove the fuel pump and gauge assembly from the service hole completely.
note For disassembly and reassembly of the fuel pump and gauge assembly, refer to .
10.Replace the fuel pump and gauge assembly gasket with a new one.

11.
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 inside the fuel tank.
  • When installing the fuel pump and gauge assembly to the fuel tank, check that the gauge moving area moves smoothly.
While inserting the fuel pump and gauge assembly into the fuel tank from the service hole, connect the suction hose to the fuel pump and gauge assembly to install the fuel pump and gauge assembly to the fuel tank.
12.Install the fuel pump bracket plate.

13.Tighten the fuel pump and gauge assembly mounting nuts to the specified torque.
Tightening torque: 2.5 ± 0.4 N·m

14.Pull up the retainer of fuel main pipe to unlock before installing.

15.
caution
  • When pushing in the retainer of the fuel main pipe connector, pay attention to avoid damage to the retainer.
  • After the installation of the fuel main pipe, slightly pull the fuel main 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 to the fuel pump and gauge assembly securely and push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump and gauge assembly.

16.Connect the fuel pump and gauge assembly connector.

17.Install the floor inspection lid (RH).
18.Install the second seat assembly (Refer to GROUP 52A - Second Seat Assembly ).