FUEL PUMP INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the fuel pump Click here.

PROCEDURE


  1. INSPECT FITTING OF FUEL PUMP GAUGE RETAINER


    1. Inspect the fuel pump gauge retainer.


      1. Install the fuel pump gauge retainer to the fuel tank by hand with the fuel suction with pump assembly disconnected.


        • If the fuel pump gauge retainer can be turned 180° or more by hand, reuse the retainer.

        • If the fuel pump gauge retainer cannot be turned 180° or more by hand, replace it with a new one.

        Tech Tips

        Check that there is no damage, dents, foreign matter, or other defects on the threads of the fuel tank.

  2. INSTALL FUEL SUCTION WITH PUMP ASSEMBLY


    1. A00552VE05
      Text in Illustration
      *1 New Gasket

      Install a new gasket onto the fuel tank.

    2. A00589QE02

      Set the fuel suction with pump assembly to the fuel tank.

      Note

      Make sure that the fuel sender gauge arm does not bend.

    3. Align the protrusion of the fuel suction with pump assembly with the notch of the fuel tank.

      Text in Illustration
      *1 Notch
      *2 Protrusion
    4. A0058JFE04
      Text in Illustration
      *1

      Start Mark

      (Fuel Tank)
      *2

      Start Mark

      (Retainer)

      While holding the fuel suction with pump assembly by hand to prevent it from tilting, align the starting marks on the fuel pump gauge retainer and fuel tank and tighten the fuel pump gauge retainer 180° by hand.

      Tech Tips


      • Check that there is no damage, dents, foreign matter, or other defects on the threads of the fuel tank.

      • The diameter of a supplied fuel pump gauge retainer is larger than that of the factory-installed retainer, anticipating that the fuel tank swells and expands over time. If the diameter of the factory-installed retainer is too small to reinstall, use a supplied fuel pump gauge retainer.

    5. Set the fuel pump gauge retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer one complete turn by hand.

    6. A0054YTE01

      Temporarily install SST (plate and 4 claws) to the fuel pump gauge retainer.

      SST
      09808-14030
      09808-01070

      Tech Tips


      • Be sure to use 4 SST (claws) as shown in the illustration.

      • Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.

    7. While pressing SST (claws) against the fuel pump gauge retainer ribs securely, install the 4 bolts.

      Tech Tips

      Install SST while pressing SST (claws) against the fuel pump gauge retainer (toward the center of SST).

    8. Install SST (handle).

    9. A0052B0E01
      Text in Illustration
      *1 Mark
      *a Front Side

      Tighten the fuel pump gauge retainer approximately 270° so that the start mark on the retainer is in the position shown in the illustration.

      Note


      • Do not use any tools other than those specified in this operation. Damage to the fuel pump gauge retainer or fuel tank may result.

      • 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 SST (handle) 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 (bolts) and reinstall SST.

      Tech Tips

      The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

  3. CONNECT NO. 2 FUEL TANK EVAPORATION TUBE


    1. A0053XAE01
      Text in Illustration
      *1 Retainer

      Connect the No. 2 fuel tank evaporation tube to the fuel suction with pump assembly.

  4. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A0056AU

      Connect the No. 1 charcoal canister outlet hose to the fuel suction with pump assembly.

      Tech Tips

      After connecting the No. 2 fuel tank evaporation tube and No. 1 charcoal canister outlet hose, check that the No. 2 fuel tank evaporation tube is positioned below the No. 1 charcoal canister outlet hose.

  5. CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A00543N

      Connect the No. 1 fuel evaporation tube sub-assembly to the fuel suction with pump assembly with the clip.

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Push the fuel tube joint into the plug of the fuel suction with pump assembly, and then install the tube joint clip.

      A0055QVE01
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring

      Note


      • Check that there are no scratches or foreign objects around the connected part of the fuel tube joint and plug before performing this work.

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

      • Check that the tube joint clip is on the collar of the fuel tube joint.

      • After installing the tube joint clip, check that the fuel tank main tube cannot be pulled out.

    2. A0054MF

      Connect the fuel pump connector.

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  8. INSPECT FOR FUEL LEAK

    Click here

  9. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. A0054AF

      Install the rear floor service hole cover with new butyl tape.

  10. INSTALL NO. 1 QUARTER WHEEL HOUSE GUSSET SUB-ASSEMBLY

    Click here

  11. INSTALL REAR BENCH TYPE SEAT CUSHION ASSEMBLY (for Sedan)

    Click here

  12. INSTALL REAR BENCH TYPE SEAT CUSHION ASSEMBLY (for Wagon)

    Click here