FUEL PUMP INSTALLATION

PROCEDURE


  1. INSTALL FUEL SUCTION WITH PUMP ASSEMBLY


    1. A00552VE05
      Text in Illustration
      *1 New Gasket

      Install a new gasket onto the fuel tank.

    2. A00589QE02
      Text in Illustration
      *1 Notch
      *2 Protrusion

      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.

  2. INSTALL FUEL PUMP GAUGE RETAINER


    1. A0054VSE01
      Text in Illustration
      *a Co-rotation Prevention Check Mark
      A0054DN Front Side of Vehicle

      Apply a co-rotation prevention check mark to the fuel suction with pump and gauge tube assembly.

      Tech Tips

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

    2. A0053O5E02
      Text in Illustration
      *a Start Mark (Fuel Tank Assembly)
      *b Start Mark (Fuel Pump Gauge Retainer)
      A0054DN Front Side of Vehicle

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

      Note

      Replace the fuel pump gauge retainer with a new one if not installed properly.

      Tech Tips

      Make sure the start marks on the fuel pump gauge retainer and fuel tank assembly are aligned, and then tighten the fuel pump gauge retainer.

    3. A0054BQE02
      Text in Illustration
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Rib
      *c Cutout
      *d SST (Claw Set) Incorrect Installation Point (Rotational Start Point Mark of Fuel Pump Gauge Retainer)

      Install SST to the fuel pump gauge retainer.


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

        SST
        09808-14031   ( 09808-01080, 09808-01090, 09808-01100 )

        Note


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

        • Do not place SST on the rotational start point mark of the fuel pump gauge retainer, otherwise SST (claw set) cannot be set correctly.

      2. A0057LME02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        A0054DN Press
        A0057VO SST (Bolt)

        While firmly pressing the claw of SST into rib of the fuel pump gauge retainer, tighten the bolt.

      3. A0057S0E02
        Text in Illustration
        *a SST (Plate)
        *b SST (Claw Set)
        A0054DN SST (Bolt)

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

        SST
        09808-14031   ( 09808-01090, 09808-01030 )
      4. A00575XE02
        Text in Illustration
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        A0054DN 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. A00567GE02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        A0054DN Press

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

    4. A0054SGE02
      Text in Illustration
      *a SST (Plate)
      *b Start Mark (Fuel Pump Gauge Retainer)
      *c Worker A
      *d Worker B
      *e Approximately 180°
      *f Co-rotation Prevention Check Mark
      A0054DN Press Down
      A0057VO Slowly Rotate
      A0052FQ Front Side of Vehicle

      While one person presses down to prevent the fuel pump gauge retainer and the fuel suction with pump and gauge tube assembly from rotating together, the other person should firmly press the fuel pump gauge retainer against the threads of the fuel tank assembly, and tighten it by rotating it approximately 180°.

      CAUTION:

      Make sure not to pinch your hands with SST.

      Note


      • Be careful not to apply excessive downward force to SST, as this may damage the fuel suction with pump and gauge tube assembly or fuel tank assembly.

      • Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so make sure SST is horizontal when turning it.

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

      • Do not rotate the fuel pump gauge retainer when the co-rotation prevention check mark is out of place.

    5. As shown in the illustration, quickly and firmly press down on the part of the fuel pump gauge retainer closest to the front side of the vehicle so that it no longer rises up.

      A0056TKE02
      Text in Illustration
      *1 Fuel Pump Gauge Retainer *2 Fuel Tank Assembly
      *a SST (Plate) *b Press Quickly and Firmly
      *c Fuel Pump Gauge Retainer Rise Up Area *d Front Side of Vehicle

      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 pressing down the fuel pump gauge retainer, there will be a sound or feeling of parts contacting and pressing together when the fuel pump gauge retainer is fully pressed down, and at this point it will stop rising up.

    6. A0054FYE02
      Text in Illustration
      *a SST (Plate)
      *b Start Mark (Fuel Pump Gauge Retainer)
      *c Start Mark (Fuel Tank Assembly)
      *d Worker A
      *e Worker B
      *f Rotate to Start Mark on Fuel Tank Assembly
      A0054DN Press Down
      A0057VO Slowly Rotate
      A0052FQ Front Side of Vehicle

      While one person presses down to prevent the fuel pump gauge retainer and the fuel suction with pump and gauge tube assembly from rotating together, the other person should slowly rotate SST (plate) and tighten the fuel pump gauge retainer until it reaches the start mark on the fuel tank assembly.

      CAUTION:

      Make sure not to pinch your hands with SST.

    7. A0054QIE02
      Text in Illustration
      *1 Fuel Pump Gauge Retainer
      *2 Fuel Tank Assembly
      *a Measurement Location
      *b Vernier Caliper
      A0054DN Front Side of Vehicle

      Check the tightening condition of the fuel pump gauge retainer.


      1. Using a vernier caliper, measure the upper surface of the fuel tank assembly in the 3 locations shown in the illustration.

        Specification
        Difference between the 3 measured values is within 3.0 mm (0.118 in.).

        Note

        If the difference between measurements is approximately 6.0 mm (0.236 in.), the threads are cross-threaded by one row (6.0 mm (0.236 in.)), so remove and reinstall the fuel pump gauge retainer.

    8. A0057IHE02
      Text in Illustration
      *a SST (Handle)
      *b SST (Plate)
      *c Start Mark (Fuel Pump Gauge Retainer)
      *d Worker A
      *e Worker B
      *f Approximately 90°
      A0054DN Press Down
      A0057VO Slowly Rotate
      A0052FQ Front Side of Vehicle

      Install SST (handle) to SST (plate).

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

    9. While one person presses down to prevent the fuel pump gauge retainer and the fuel suction with pump and gauge tube assembly from rotating together, the other person should slowly rotate SST (handle) and tighten the fuel pump gauge retainer by approximately 90°.

      CAUTION:

      Make sure not to pinch your hands with SST.

    10. A00595BE02
      Text in Illustration
      *a SST (Handle)
      *b SST (Plate)
      *c Copy of Fully Tightened Mark
      *d Start of Threads of the Fuel Pump Gauge Retainer
      A0054DN Tighten
      A0057VO 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.

  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