Removal (Aerio)
- Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable, and go to next step.
- Hoist vehicle and remove muffler.
- Remove EVAP canister and it's bracket from vehicle. Disconnect fuel filler hose and breather hose from filler neck, then disconnect filter inlet hose from canister air suction filter.
- Disconnect fuel filler hose and breather hose(s) from fuel filler neck (car body side). See Fig 1 . Insert hose of a hand operated fuel siphon pump into rubber hose, but not into tank. Siphon fuel into a fuel certified container. Remove siphon hose, and go to next step.
- Disconnect fuel pipe joints from fuel pipes. Disconnect quick joint as follows:
- Remove mud, dust and/or foreign material between pipe and joint by blowing compressed air.
- Unlock joint lock by inserting Quick Disconnect Tool (09919-47020) between pipe and joint, then disconnect joint from pipe.
- Support fuel tank with jack and remove its mounting bolts. Lower fuel tank a little in order to disconnect fuel pump connector, tank pressure sensor connector and ground wire harness. Remove fuel tank.
- Disconnect fuel cut valve hose, fuel feed line and return fuel pipe from fuel pump assembly. Use Quick Disconnect Tool (09919-47020) when disconnecting fuel feed pipe and fuel return pipe. Remove fuel pump assembly from fuel tank.
- While opening snap fit locks, removing fuel filter. Slide fuel level gauge out of position and remove. See Fig 2 . Also remove bracket at bottom of fuel pump by opening snap fit locks and sliding it out of position. Go to next step.
- Disconnect fuel pump lead wires from pump (not at fuel pump) assembly. Remove fuel pump with lead wires, grommet and spacer from pump assembly. Inspect all fuel pump components thoroughly before assembly. Replace worn or damaged components as necessary.
NOTE:
DO NOT put siphon hose through filler neck at fuel filler cap. To avoid damaging inlet valve, DO NOT force pump hose into fuel tank.
WARNING:
A small amount of fuel may be released after hose is disconnected. Cover hose and pipe to be disconnected with a shop towel in order to reduce risk of personal injury.
CAUTION:
When disassembling fuel pump assembly, be careful not to damage case around grommet area or oil leakage from fuel pump may occur. Use of a NEW grommet is recommended. Apply engine oil to grommet before installation.