RM38T0EC _51 Engine / Hybrid System _144959 M20F-FXS, M20G-FXS FUEL _0604273 FUEL PUMP A

M20F-FXS, M20G-FXS FUEL  FUEL PUMP  REMOVAL  


CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)
A545572N01
4.719,1.635 5.052,1.635 false 5.885,2.438 6.219,2.438 false 1.5,2.781 1.25,2.417 1.25,2.417 1.083,2.417 false 5.854,4.042 6.188,4.042 false 5.823,3.656 6.156,3.656 false 2.979,4.458 3.313,4.458 false 2.083,3.75 2.417,3.75 false 2.198,2.333 2.531,2.333 false 1.208,1 1.208,1.333 false 6.5,0.24 6.833,0.24 false 6.458,0.656 6.792,0.656 false 5.698,4.51 6.031,4.51 false 5.5,3.24 5.833,3.24 false 3.583,3.188 3.583,3.583 false 6.01,0.073 6.646,0.396 0.635,0.323 18 false 1, 2 6.25,0.49 6.594,0.844 0.344,0.354 18 false 3 4.531,1.458 4.875,1.813 0.344,0.354 18 false 5 6.24,3.469 6.583,3.823 0.344,0.354 18 false 9 6.25,3.854 6.594,4.208 0.344,0.354 18 false 11 0.875,2.208 1.219,2.563 0.344,0.354 18 false 6 1.146,1.323 1.49,1.677 0.344,0.354 18 false 4 3.573,3.615 3.917,3.969 0.344,0.354 18 false 8 1.74,3.573 2.083,3.927 0.344,0.354 18 false 13 6.281,2.323 6.438,2.521 0.156,0.198 10 false ● 3.365,4.354 3.521,4.552 0.156,0.198 10 false ● 6.313,4.344 6.656,4.698 0.344,0.354 18 false 12 2.813,2.177 3.156,2.531 0.344,0.354 18 false 10 5.875,3.063 6.219,3.417 0.344,0.354 18 false 7

Procedure Part Name Code
Z101186

Z101188

Z101187

1 PRECAUTION - (Click here) - -
2 DISCHARGE FUEL SYSTEM PRESSURE - (Click here) - -
3 DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL - - - -
4 REAR SEAT ASSEMBLY - - - -
5 REAR FLOOR SERVICE HOLE COVER 58325M - - -
6 FUEL TANK PRESSURE SENSOR (VAPOR PRESSURE SENSOR) 89461 (Click here) - -
7 NO. 1 FUEL TUBE CLAMP 77285J - - -
8 FUEL TANK VENT HOSE SUB-ASSEMBLY 77404A (Click here) - -
9 FUEL GAUGE WIRE 82412 - - -
10 FUEL TANK MAIN TUBE SUB-ASSEMBLY 77209F (Click here) - -
11 NO. 4 FUEL TUBE CLAMP 77289C - - -
12 FUEL PUMP GAUGE RETAINER 77144 (Click here) - -
13 FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 77020A (Click here) - -

● Non-reusable part - -

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel pump removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Replacement of Fuel pump (for low pressure side) Inspection after repair
·

Poor idle, etc.

·

Engine start function, etc.


(Click here)

CAUTION:
·
A360563

Never perform work on fuel system components near any possible ignition sources.

·

Vaporized fuel could ignite, resulting in a serious accident.


·

Do not perform work on fuel system components without first disconnecting the cable from the negative (-) auxiliary battery terminal.

·

Sparks could cause vaporized fuel to ignite, resulting in a serious accident.



NOTICE:

After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 120 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.


HINT:

When the cable is disconnected/reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

·

Learning completes when vehicle is driven

Effect/Inoperative Function When Necessary Procedures are not Performed Necessary Procedures Link
Front camera system Drive the vehicle straight ahead at 15 km/h (10 mph) or more for 1 second or more. (Click here)

·

Learning completes when vehicle is operated normally

Effect/Inoperative Function When Necessary Procedures are not Performed Necessary Procedures Link
Power door lock control system
·

Back door opener


Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch. (Click here)
Power back door system Fully close the back door by hand.
HINT:

Initialization is not necessary if the above procedures are performed while the back door is closed.


(Click here)
Air conditioning system After the ignition switch is turned to ON, the servo motor standard position is recognized. -



PROCEDURE

Hide 1. PRECAUTION

Z101186

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

Click here(Click here)



Hide 58325M 5.REMOVE REAR FLOOR SERVICE HOLE COVER

a.
A545574C01
1.125,0.531 0.844,0.823 true 0.635,0.729 0.844,0.917 0.208,0.188 10 true *a
*a Protective Tape - -



Hide 89461 6.REMOVE FUEL TANK PRESSURE SENSOR (VAPOR PRESSURE SENSOR)

Z101186

Click here(Click here)

Hide 77285J 7.REMOVE NO. 1 FUEL TUBE CLAMP

a.
A545576


Hide 77404A 8.DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY

a.
A545577N01
1.479,0.146 1.76,0.5 0.281,0.354 18 false i

i.

Disconnect the fuel tank vent hose sub-assembly from the fuel suction tube with pump and gauge assembly.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (FUEL)>FUEL SYSTEM>PRECAUTION



Hide 82412 9.REMOVE FUEL GAUGE WIRE

a.
A545578


Hide 77209F 10.DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

a.
A545579C01
4.948,0.865 4.781,1.104 false 1.198,0.625 1.094,0.792 true 1.698,0.417 1.521,0.188 true 5.771,0.167 5.542,0.313 false 4.896,0.188 5.094,0.323 false 5.271,0.729 4.583,0.729 false 6.198,0.979 5.771,0.979 true 6.01,0.969 6.01,0.854 6.01,0.854 5.76,0.854 true 4.698,1.135 5.01,1.292 0.313,0.156 10 false *1 1.01,0.813 1.198,0.979 0.188,0.167 10 true *2 1.323,0.094 1.49,0.271 0.167,0.177 10 true *3 5.823,0.063 6.135,0.219 0.313,0.156 10 false *a 6.229,0.875 6.542,1.031 0.313,0.156 10 false *b 4.729,0.083 5.042,0.24 0.313,0.156 10 false *c 4.396,0.615 4.708,0.771 0.313,0.156 10 false *2 0.427,0.073 0.708,0.427 0.281,0.354 18 false i
*1 Fuel Suction Plate Sub-assembly *2 Tube Joint Clip
*3 Fuel Tank Main Tube Sub-assembly - -
*a Fuel Tube Joint *b O-ring
*c Nylon Tube - -
V100135

Pull off
V100136

Pull off


i.

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

NOTICE:
·

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.

·

Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.

·

If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.





Hide 77289C 11.REMOVE NO. 4 FUEL TUBE CLAMP

a.
A545581


Hide 77144 12.REMOVE FUEL PUMP GAUGE RETAINER

a.
A503937C01
1.219,2.458 1.719,2.656 true 2.104,1.802 2.385,1.969 true 2.104,1.438 2.76,1.125 true 2.229,1.573 2.823,1.573 true 1.323,0.792 1.708,0.792 true 5.354,0.156 5.771,0.271 true 4.615,1.292 5.25,0.938 true 5.573,1.448 6.219,1.365 true 5.521,1.594 5.01,1.938 true 5.615,1.771 5.417,2.083 true 6.521,2.219 6.938,2.219 true 5.542,0.688 5.927,0.688 true 1.74,2.573 1.938,2.729 0.198,0.156 10 true *a 2.844,1.469 3.031,1.646 0.188,0.177 10 true *b 2.417,1.875 2.604,2.063 0.188,0.188 10 true *c 2.771,1.031 2.958,1.208 0.188,0.177 10 true *d 5.156,0.052 5.333,0.219 0.177,0.167 10 true *e 1.125,0.698 1.313,0.875 0.188,0.177 10 true *d 4.406,1.198 4.594,1.375 0.188,0.177 10 true *d 6.26,1.25 6.448,1.427 0.188,0.177 10 true *d 4.823,1.875 5.01,2.052 0.188,0.177 10 true *b 5.354,2.094 5.542,2.281 0.188,0.188 10 true *c 6.958,2.104 7.146,2.292 0.188,0.188 10 false *c 0.365,0.063 0.646,0.417 0.281,0.354 18 false i 3.927,0.031 4.771,0.292 0.844,0.26 18 true iii, iv, v 2,2.188 2.177,2.438 0.177,0.25 18 true ii 5.917,0.573 6.104,0.75 0.188,0.177 10 true *f
*a Insertion Point *b SST (Plate)
*c SST (Claw) *d SST (Bolt)
*e SST (Handle) *f Extension Bar


i.

Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

SST
09808-01071  
09808-14031  (09808-01030, 09808-01090)

HINT:

Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.



ii.

While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).


iii.

Install SST (handle) to SST (plate).

SST
09808-01071  
09808-14031  (09808-01010, 09808-01030, 09808-01090)


iv.

Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

NOTICE:
·

Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.

·

Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.

·

Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.

·

Do not spin SST too fast or use an impact wrench as this may result in damage to components.

·

If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.




v.

While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.



Hide 77020A 13.REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

a.
A545582N01
0.375,0.031 0.656,0.385 0.281,0.354 18 false i 3.729,0.042 4.01,0.396 0.281,0.354 18 false ii

i.

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

NOTICE:

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



ii.

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