RM3660EC _51 Engine / Hybrid System _080750 NR Series FUEL _0393849 FUEL PUMP A

NR Series FUEL FUEL PUMP REMOVAL

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 with filter assembly 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 with filter assembly	Inspection after repair	· Poor idle, etc. · Engine start function, etc.	(201906,999999,_51,_080777,_0393969,RM100000001I1RE,)

CAUTION:: ·

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 (-) battery terminal.

·

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

HINT:

When the cable is disconnected / reconnected to the 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 Procedure not Performed	Necessary Procedure	Link
Stop and Start System	Idle the engine for approximately 5 to 60 minutes or drive the vehicle until stop and start control is permitted	(201906,999999,_51,_080774,_0393362,RM100000001HXHC,)
Pre-collision System	Perform steering sensor zero point calibration	(202304,999999,_95,_139716,_0601175,RM100000002BFOE,)
Lane Tracing Assist System	Perform steering sensor zero point calibration	(202304,999999,_95,_139716,_0601175,RM100000002BFOE,)

PROCEDURE

Hide Display 1. PRECAUTION

NOTICE:: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal.; Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>BEFORE DISCONNECTING BATTERY202304,202502,_V1,_143216,_0598315,RM100000002B3MI,202502,999999,_V1,_143216,_0598315,RM100000002RP07,

Hide Display 2. DISCHARGE FUEL SYSTEM PRESSURE

Click hereEngine / Hybrid System>NR Series (FUEL)>FUEL SYSTEM>PRECAUTION202304,999999,_51,_080750,_0393845,RM100000002BH2H,

Hide Display 3.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Click hereGeneral>MAINTENANCE>NR Series BATTERY>REMOVAL202304,999999,_V1,_080956,_0392375,RM100000002BCCL_05_0005,

Hide Display 4.REMOVE REAR SEAT ASSEMBLY

for Fixed Seat Type:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for Fixed Seat Type)>REMOVAL201906,999999,_58,_080732,_0394195,RM100000001I3KD,

for Fold Down Seat Type:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for Fold Down Seat Type)>REMOVAL201906,999999,_58,_080732,_0394196,RM100000001I3KH,

Hide Display 58325E 5.REMOVE REAR FLOOR SERVICE HOLE COVER

0.813,0.74 1.104,0.271 1.104,0.271 1.24,0.271 true 1.313,0.177 1.542,0.396 0.229,0.219 10 true *a

*a	Protective Tape

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

Disconnect the fuel suction tube with pump and gauge assembly connector.

Hide Display 77404 6.DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY

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

Click hereEngine / Hybrid System>NR Series (FUEL)>FUEL SYSTEM>PRECAUTION202304,999999,_51,_080750,_0393845,RM100000002BH2H,

Hide Display 77209F 7.DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

1.292,0.865 1.25,0.417 1.25,0.417 1.063,0.417 true 1.531,2.833 1.417,2.594 1.417,2.594 1.271,2.594 false 0.51,1.115 0.51,0.833 true 2.083,2.802 2.26,2.594 2.26,2.594 2.417,2.594 false 2.417,3.313 2.781,3.313 false 1,3.802 1.135,3.802 1.135,3.802 1.25,3.479 false 2.188,3.604 2.833,3.604 true 2.188,3.448 2.667,3.448 2.667,3.448 2.667,3.594 true 0.781,3.74 1.25,4.052 0.469,0.313 10 false *1 2.875,3.229 3.219,3.448 0.344,0.219 10 false *2 0.813,0.344 1.01,0.531 0.198,0.188 10 true *3 2.51,2.5 2.906,2.906 0.396,0.406 10 false *a 2.906,3.531 3.25,3.948 0.344,0.417 10 false *b 1.063,2.5 1.469,2.844 0.406,0.344 10 false *c 0.427,1.135 0.625,1.323 0.198,0.188 10 true *2

*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
	Pull off
	Pull off

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 Display 77144 8.REMOVE FUEL PUMP GAUGE RETAINER

Disengage the 2 claws to remove the No. 1 fuel tube clamp.

Remove the fuel pump gauge retainer.

1.01,0.302 1.542,0.302 true 2.635,0.406 2.813,0.406 true 2.115,1.031 2.656,1.031 true 2.177,1.927 2.177,1.49 true 0.854,3.052 1.625,3.052 true 1.698,2.958 1.99,3.323 0.292,0.365 10 true *a 2.865,0.344 3.052,0.531 0.188,0.188 10 true *b 2.115,1.938 2.281,2.135 0.167,0.198 10 true *c 0.813,0.208 1,0.396 0.188,0.188 10 true *d 2.688,0.958 2.885,1.135 0.198,0.177 10 true *d

*a	Insertion Point
*b	SST (Plate)
*c	SST (Claw)
*d	SST (Bolt)

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.

0.594,0.396 0.75,0.396 0.75,0.396 1.167,0.792 true 1.719,2.427 2.323,2.427 true 0.958,1.323 1.115,1.323 1.115,1.323 1.49,1.146 true 1.896,1.688 2.406,1.688 true 1.729,1 2.24,1 true 2.302,1.26 2.813,1.26 true 0.375,0.323 0.573,0.5 0.198,0.177 10 true *a 2.854,1.188 3.052,1.354 0.198,0.167 10 true *b 1.49,2.344 1.688,2.552 0.198,0.208 10 true *c 2.448,1.604 2.646,1.792 0.198,0.188 10 true *d 0.771,1.25 0.948,1.406 0.177,0.156 10 true *d 2.302,0.917 2.5,1.094 0.198,0.177 10 true *e

*a	SST (Handle)
*b	SST (Plate)
*c	SST (Claw)
*d	SST (Bolt)
*e	Extension Bar

Install SST (handle) and an extension bar to SST (plate).

SST: 09808-14031 (09808-01010)

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.

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

Hide Display 77020A 9.REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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.

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