CANISTER INSTALLATION

PROCEDURE


  1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY

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  2. INSTALL FUEL PUMP

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  3. INSTALL FUEL SENDER GAUGE ASSEMBLY

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  4. INSTALL FUEL SUCTION TUBE SET GASKET


    1. Apply gasoline to a new fuel suction tube set gasket and install it to the fuel tank assembly.

  5. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B0047SY

      Align the tab of the fuel suction tube with pump and gauge assembly with the groove of the fuel tank assembly.

      Note

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

    2. B0046YEC01
      *a Paint Mark
      B0046MU Front Side of Vehicle

      Place a paint mark on the fuel suction tube with pump and gauge assembly as shown in the illustration.

      Tech Tips

      Perform this step only when replacing the fuel suction tube with pump and gauge assembly.

  6. INSTALL FUEL PUMP GAUGE RETAINER


    1. B0045I6C01
      *a Copy of Start of Threads Mark
      *b Start of Threads of the Fuel Pump Gauge Retainer
      *c Align
      B0046MU Press down
      B0045SR Front Side of Vehicle

      Align the start of the threads of a new fuel pump gauge retainer with the start of threads mark that was copied onto the vehicle body while pushing down the fuel suction tube with pump and gauge assembly, attach the fuel pump gauge retainer.

    2. Install SST to the fuel pump gauge retainer.


      1. B0045P8C02
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Protrusion
        *c Notch
        *d Do not install SST (Claw Set)

        Set 4 SST (claw set) to the fuel pump gauge retainer.

        SST
        09808-14031   ( 09808-01080, 09808-01100 )

        Note


        • Align the notch of SST (claw set) with the protrusion of the fuel pump gauge retainer.

        • Do not install SST (claw set) to the start of threads location of the fuel pump gauge retainer.

      2. B0045B3C02
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        B0046MU Push
        B0045SR SST (Bolt)

        Push SST (claw set) against the fuel pump gauge retainer and tighten SST (bolt).

      3. B00470NC01
        *a SST (Plate)
        *b SST (Claw Set)
        B0046MU SST (Bolt)

        Temporarily install SST (plate) to SST (claw set) with 4 SST (bolt).

        SST
        09808-14031   ( 09808-01030, 09808-01090 )
      4. B0047QJC01
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        B0046MU Front Side of Vehicle

        Adjust the position of SST (claw set) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.

      5. B00481TC02
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        B0046MU Press

        Press SST (claw set) against the rib of the fuel pump gauge retainer and tighten SST (bolt).

    3. B0046DAC01
      *1 Fuel Pump Gauge Retainer
      *2 Fuel Tank Assembly
      *a SST (Plate)
      *b Tighten approximately 180°
      *c Fuel pump gauge retainer rises up
      *d Cross Section
      *e Paint Mark
      B0046MU Press quickly and firmly
      B0045SR Front Side of Vehicle

      While pressing down on the fuel suction tube with pump and gauge assembly, have another person firmly press the fuel pump gauge retainer against the threads of the fuel tank assembly, and tighten the fuel pump gauge retainer by approximately 180°.

      Note


      • To prevent damage to parts, do not turn SST too vigorously.

      • Do not turn the fuel pump gauge retainer if the paint marks become misaligned.

    4. Quickly and firmly press down on the part of the fuel pump gauge retainer closest to the front of the vehicle to keep it from rising up.

      Tech Tips


      • If the fuel pump gauge retainer cannot be properly pressed down due to the position of SST, set SST in a different position.

      • When fully pressing down the fuel pump gauge retainer, there will be a sound or tactile sensation of parts contacting each other, and at this point the fuel suction tube with pump and gauge assembly will stop rising up.

    5. B0046SDC01
      *a SST (Plate)
      *b One Person in Charge of Tightening
      *c One Person in Charge of Pressing Down
      *d Approximately 270°
      *e Fuel Pump Gauge Retainer Start of Threads Location
      B0046MU Press Down
      B0045SR Slowly Rotate
      B0047LS Front Side of Vehicle

      While pressing down on the fuel suction tube with pump and gauge assembly, have another person slowly tighten the fuel pump gauge retainer by approximately 270°.

    6. Check the tightening status of the fuel pump gauge retainer.


      1. B0048A2C01
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Assembly
        *a Measurement Position
        *b Vernier Caliper
        B0046MU Front Side of Vehicle

        Using a vernier caliper, measure the distance from the fuel tank assembly to the upper surface of the fuel pump gauge retainer at 3 positions as shown in the illustration.

        Standard
        Difference between the 3 measured values is 3 mm (0.118 in.) or less.

        Note

        If the difference between measurements is approximately 6 mm (0.236 in.), the threads are cross-threaded by 1 row (6 mm (0.236 in.)), so remove and reinstall the fuel pump gauge retainer.

    7. B0045C0C01
      *a SST (Handle)
      *b SST (Plate)
      *c One Person in Charge of Tightening
      *d One Person in Charge of Pressing Down
      *e Approximately 60°
      B0046MU Front Side of Vehicle

      Install SST (handle) to SST (plate).

      SST
      09808-14031   ( 09808-01010, 09808-01020 )

    8. While pressing down on the fuel suction tube with pump and gauge assembly, have another person use SST (handle) to slowly tighten the fuel pump gauge retainer approximately 60°.

    9. B00463QC01
      *a SST (Handle)
      *b SST (Plate)
      *c Copy of Fully Tightened Mark
      *d Start of Threads of the Fuel Pump Gauge Retainer
      *e Fully Tightened Position
      B0046MU Tighten
      B0045SR Front Side of Vehicle

      Slowly tighten the fuel pump gauge retainer until it reaches the fully tightened mark that was copied onto the vehicle body.

  7. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Connect the fuel tank main tube sub-assembly to the fuel suction tube with pump and gauge assembly.

    2. B004560C01
      *1 Tube Joint Clip
      *2 Fuel Suction Plate Sub-assembly
      *a Fuel Tube Joint
      *b Nylon Tube
      *c Rib
      *d Correct
      *e Incorrect

      Install the tube joint clip.

      Note


      • Make sure there is no damage to or foreign matter on the connecting surfaces.

      • Check that the fuel tube joint is correctly and fully inserted.

      • Check that the tube joint clip is above the rib of the fuel tube joint.

      • After installing the tube joint clip, make sure the fuel tube joint is secure.

      • Do not damage any of the clips. If a tube joint clip is damaged, replace it.

  8. CHECK AIRTIGHTNESS


    1. B0045NIC01
      *a Vacuum Pump
      *b Port B

      Install a vacuum pump to port B of the fuel suction tube with pump and gauge assembly as shown in the illustration.

    2. B00467ZC01
      B0045T7 Apply Soapy Water Here

      Apply soapy water to the contact areas between the fuel suction tube with pump and gauge assembly and the fuel pump gauge retainer.

      Note

      Cover the connecters of the fuel suction tube with pump and gauge assembly with protective tape.

    3. B00479XC01
      *a Port A
      *b Port B
      *c Vacuum Pump

      Close port A and use the vacuum pump to apply 5 kPa (0.1 kgf/cm2, 1 psi) of compressed air to port B as shown in the illustration.

      Note

      Do not apply more compressed air than necessary.

    4. Check that the contact areas between the fuel suction tube with pump and gauge assembly and fuel pump gauge retainer are airtight.

      Note


      • If air bubbles appear, remove and reinstall the fuel pump gauge retainer.

      • After a fuel pump gauge retainer and fuel suction tube set gasket have been used once, replace them with new parts.

      • When removing and reinstalling the fuel pump gauge retainer, make sure to clean away the soapy water to prevent the fuel suction tube set gasket from slipping out of position and being assembled incorrectly.

      Tech Tips

      If the assembled components are not airtight due to improper installation of the fuel pump gauge retainer, etc., air bubbles will appear as shown in the illustration.

      B0045IEC01
      *a Air Bubbles

  9. CONNECT NO. 1 CANISTER OUTLET HOSE SUB-ASSEMBLY


    1. Connect the No. 1 canister outlet hose sub-assembly to the fuel suction tube with pump and gauge assembly.

  10. CONNECT NO. 2 FUEL EMISSION TUBE


    1. Connect the No. 2 fuel emission tube to the fuel suction tube with pump and gauge assembly and slide the hose clip to secure it.

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  12. ADD FUEL

  13. INSPECT FOR FUEL LEAK

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  14. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. Fully remove any butyl tape remaining on the rear floor service hole cover and vehicle floor.

    2. Connect the fuel suction tube with pump and gauge assembly connector.

    3. B00482NC02
      B0045T7 Butyl Tape

      Apply a new butyl tape to the rear floor service hole cover as shown in the illustration.

    4. B0045VAC01
      *a Alignment Mark

      Align the 2 alignment marks, and install the rear floor service hole cover to the vehicle floor.

    5. B0047OR

      Install a new wiring harness protector to the rear floor service hole cover and vehicle floor as shown in the illustration.

  15. INSTALL REAR SEATBACK CENTER HINGE SUB-ASSEMBLY

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  16. INSTALL REAR SEAT ASSEMBLY LH

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  17. INSTALL REAR SEAT ASSEMBLY RH

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  18. INSTALL SPARE WHEEL COVER

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  19. INSTALL DECK BOARD ASSEMBLY

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