FUEL PUMP INSTALLATION

PROCEDURE


  1. INSTALL FUEL SENDER GAUGE ASSEMBLY

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  2. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. Apply a light coat of fuel to a new gasket and install the gasket to the fuel tank assembly.

    2. Install the fuel suction with pump and gauge tube assembly to the fuel tank assembly.

      Note

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

    3. A004TCHE02
      Text in Illustration
      *a Notch
      *b Protrusion

      Align the protrusions of the fuel suction with pump and gauge tube assembly with the notches of the fuel tank assembly.

  3. INSTALL FUEL PUMP GAUGE RETAINER


    1. A004PAHE01
      Text in Illustration
      *a Co-rotation Prevention Check Mark
      A004NPW 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. A004TVHE02
      Text in Illustration
      *a Start Mark (Fuel Tank Assembly)
      *b Start Mark (Fuel Pump Gauge Retainer)
      A004NPW 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. A004SOAE02
      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. A004ON6E02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        A004NPW Press
        A004NAK SST (Bolt)

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

      3. A004OTJE02
        Text in Illustration
        *a SST (Plate)
        *b Hook
        A004NPW SST (Bolt)

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

        SST
        09808-14031   ( 09808-01090, 09808-01030 )
      4. A004NHKE02
        Text in Illustration
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        A004NPW 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. A004TBAE02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        A004NPW Press

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

    4. A004QEME02
      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
      A004NPW Press Down
      A004NAK Slowly Rotate
      A004PZH 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.

      A004TOFE02
      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. A004ODME02
      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
      A004NPW Press Down
      A004NAK Slowly Rotate
      A004PZH 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. Check the tightening condition of the fuel pump gauge retainer.


      1. A004QKNE02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Assembly
        *a Measurement Location
        *b Vernier Caliper
        A004NPW Front Side of Vehicle

        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. A004PL4E02
      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°
      A004NPW Press Down
      A004NAK Slowly Rotate
      A004PZH 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. A004SR8E02
      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
      A004NPW Tighten
      A004NAK 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.

  4. INSTALL TANK SUCTION TUBE SUPPORT


    1. Attach the 2 claws to install the tank suction tube support.

    2. Install the fuel tube clamp.

      Note

      Securely install the fuel tube clamp by pushing it until it makes a clicking sound.

  5. CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A004SQKE02
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tube Joint
      *3 O-Ring
      *4 Collar
      *a CORRECT
      *b INCORRECT

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

      Note


      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tube joint is inserted securely.

      • 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 tube joint cannot be pulled off.

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A004PBHE02
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tube Joint
      *3 O-Ring
      *4 Collar
      *a CORRECT
      *b INCORRECT

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

      Note


      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tube joint is inserted securely.

      • 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 tube joint cannot be pulled off.

  7. CONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY (w/ Combustion Type Power Heater)


    1. A004NVHE02
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tube Joint
      *3 O-Ring
      *4 Collar
      *a CORRECT
      *b INCORRECT

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

      Note


      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tube joint is inserted securely.

      • 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 tube joint cannot be pulled off.

  8. CHECK AIRTIGHTNESS


    1. A004UDF

      After installing the fuel suction tube, check for fuel leaks by first applying soapy water to the area where the suction plate and retainer contact, and then blow your breath forcefully through a flexible pouring spout or similar tube into the fuel inlet area.


      1. A004P2F

        Blow forcefully until the reverse flow prevention valve inside the fuel inlet activates.

        Note

        Be careful not to inhale any fuel vapor.

        Tech Tips

        There should be a faintly audible sound when the reverse flow prevention valve operates.

    2. A004PFQ

      If improper installation of the fuel suction with pump and gauge tube assembly, etc. has resulted in a condition where fuel will leak, air will leak out as shown in the illustration.

      Note

      If air leaks out, recheck the installation condition, and replace the used fuel pump gauge retainer and gasket with new ones. Also, make sure to fully clean away the soapy water. (Any remaining soapy water can cause the gasket to slip and result in an improper assembly.)

  9. INSTALL REAR FLOOR SERVICE HOLE COVER


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

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

      Note

      Be careful that the rear floor service hole cover does not overlap the protrusions of the floor panel when installing.

  10. INSPECT FOR FUEL LEAK

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  11. INSTALL REAR BENCH TYPE SEAT CUSHION ASSEMBLY