Removal [06/2015 - ]: Procedure

Refer to PROCEDURE - Step 5

1. Turn back the front floor carpet assembly.

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2. Remove the 6 bolts and No. 1 quarter wheel house gusset sub-assembly from the vehicle body.

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1. Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.

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   *a	Protective Tape

2. Disconnect the fuel pump connector.

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Refer to PRECAUTION [06/2015 - ]

1. Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

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   *1	Tube Joint Clip
   *2	Fuel Suction Plate Sub-assembly
   *3	Fuel Tank Main Tube Sub-assembly
   *a	Fuel Tube Joint
   *b	O-ring
   *c	Nylon Tube
   	Pull off
   	Pull off

   NOTE:

   • Remove any foreign matter on the fuel tube joint before performing this work.
   • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
   • Be sure to disconnect the fuel tube joint by hand.
   • Do not bend, twist, pinch or kink the nylon tube.
   • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint.
   • If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.

1. Copy the fully tightened marks and start of threads mark of the fuel tank assembly.

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   *a	Copy of Fully Tightened Mark
   *b	Copy of Start of Threads Mark
   *c	Fully Tightened Mark on Fuel Tank Assembly
   *d	Start of Threads Mark on Fuel Tank Assembly
   *e	Front

   1. Copy the start of threads mark and fully tightened marks from the fuel tank assembly to the vehicle body in order to record their locations.
2. Place paint marks on the fuel suction tube with pump and gauge assembly and vehicle body as shown in the illustration.
   NOTE:

   • The fuel suction tube with pump and gauge assembly has 2 protrusions that engage with 2 notches on the fuel tank assembly to ensure correct alignment and to prevent the fuel suction tube with pump and gauge assembly from turning during installation and removal of the fuel pump gauge retainer.
   • If the fuel pump gauge retainer is turned with the fuel suction tube with pump and gauge assembly misaligned, the fuel suction tube with pump and gauge assembly will turn with the fuel pump gauge retainer and may be damaged.
   • The paint marks are used to ensure that the fuel suction tube with pump and gauge assembly does not turn with the fuel pump gauge retainer.

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   *a	Paint Mark
   *b	Front

3. Install SST to the fuel pump gauge retainer.
   1. Temporarily install SST (plate), SST (claw) and SST (bolt) to the fuel pump gauge retainer.

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      *1	Fuel Pump Gauge Retainer
      *a	SST (Claw)
      *b	SST (Plate)
      *c	SST (Bolt)
      *d	Narrow
      *e	Wide
      *f	Correct
      *g	Incorrect

      • SST: 09808-14030 
        1. 09808-01020
        2. 09808-01030
        3. 09808-01050
      • SST: 09808-01071 
      NOTE:

      • Install SST (claw) to the correct location.
      • Do not install SST (claw) to a location where the pitch between ribs of the fuel pump gauge retainer is narrow.
   2. Adjust the position of SST (claw) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.

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      *a	Center Point of Fuel Pump Gauge Retainer

   3. Press SST (claw) against the rib of the fuel pump gauge retainer and tighten SST (bolt).
   4. Install SST (handle) to SST (plate).

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      *a	SST (Claw)
      *b	SST (Plate)
      *c	SST (Bolt)
      *d	SST (Handle)
      *e	Press down
      *f	Pull

      • SST: 09808-14030 
        1. 09808-01010
        2. 09808-01020
        3. 09808-01030
        4. 09808-01050
      • SST: 09808-01071 
      NOTE:

      The torque required to remove the fuel pump gauge retainer may be as high as 200 N*m (2039 kgf*cm, 148 ft.*lbf) due to swelling of the fuel tank assembly, so perform the procedure with 2 people.

4. While holding down on the center of SST (handle) to prevent SST from separating from the fuel pump gauge retainer, pull SST (handle) with another person pulling the opposite end of SST (handle), and slowly loosen the fuel pump gauge retainer by approximately 90°.
   NOTE:

   • Be careful not to apply excessive downward force to SST, as this may damage the fuel suction tube with pump and gauge assembly or fuel tank assembly.
   • Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so be sure SST is horizontal when turning.
   • To prevent damage to parts, do not turn SST too vigorously.
   • If SST slips off of the fuel pump gauge retainer, loosen SST (bolt) and install SST again.
5. Continue to slowly loosen the fuel pump gauge retainer while another person is pressing down on the fuel suction tube with pump and gauge assembly to keep the protrusion of the fuel suction tube with pump and gauge assembly engaged with the groove of the fuel tank assembly so that the fuel suction tube with pump and gauge assembly does not move out of position.

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   *a	SST (Claw)	*b	SST (Plate)
   *c	SST (Bolt)	*d	SST (Handle)
   *e	One Person in Charge of Loosening	*f	One Person in Charge of Pressing Down
   *g	Paint Mark	-	-

   NOTE:

   • The fuel suction tube with pump and gauge assembly is pressed against the underside of the fuel tank assembly by a spring, and the constant upward pressure applied by this spring causes the fuel suction tube with pump and gauge assembly to rise up.
   • If the fuel pump gauge retainer is turned while the fuel suction tube with pump and gauge assembly and fuel tank assembly are not correctly aligned, the fuel suction tube with pump and gauge assembly will move with the fuel pump gauge retainer, and the fuel suction tube with pump and gauge assembly and fuel tank assembly may both be damaged.
   • Do not turn the fuel pump gauge retainer if the paint marks become misaligned.

1. Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.
   NOTE:

   Be careful not to bend the arm of the fuel sender gauge assembly.

2. Remove the fuel suction tube set gasket from the fuel tank assembly.

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   *1	Fuel Suction Tube Set Gasket