FUEL PUMP INSTALLATION

PROCEDURE


  1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B001N74E05
      Text in Illustration
      *1 Gasket

      Install a new gasket onto the fuel tank.

    2. B001KKBE04
      Text in Illustration
      *1 Notch
      *2 Protrusion

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

      Note

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

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

  2. INSTALL FUEL PUMP GAUGE RETAINER


    1. B001NEIE03
      Text in Illustration
      *1 Start Mark
      *2 Mark
      *3 Front

      While holding the fuel suction tube with pump and gauge assembly by hand to prevent it from tilting, align the mark on the new fuel pump gauge retainer with the start mark on the 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.

    2. B001MXKE02
      Text in Illustration
      *1

      SST

      (Plate)

      *2

      SST

      (Claw)

      *3 Rib

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

      SST
      09808-14030   ( 09808-01030, 09808-01040, 09808-01050 )

      Tech Tips

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

    3. While pressing the claws of SST to the fuel pump gauge retainer ribs securely, tighten the bolts.

      Tech Tips

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

    4. Install the SST handle.

    5. B001N89E02
      Text in Illustration
      *1

      SST

      (Handle)

      *2

      SST

      (Plate)

      *3

      SST

      (Claw)

      *4 Mark
      *a Front Side

      Tighten the fuel pump gauge retainer approximately 360° so that the mark on the retainer comes within the range shown in the illustration.

      SST
      09808-14030   ( 09808-01010, 09808-01020, 09808-01030, 09808-01040, 09808-01050 )

      Note


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

      • Do not press down on SST excessively as this may make the retainer hard to rotate, and may damage components.

      • Make sure to rotate the SST handle horizontally. If the 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 retainer, loosen the SST bolts and reinstall SST.

      Tech Tips


      • Lightly press down on SST to prevent it from separating from the retainer. While pressing SST, rotate the handle slowly to tighten the retainer.

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

  3. CONNECT FUEL TANK EVAPORATION TUBE


    1. B001N2TE04
      Text in Illustration
      *1 Retainer

      Connect the fuel tank evaporation tube to the fuel suction tube with pump and gauge assembly.

  4. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. B001LRR

      Connect the No. 1 charcoal canister outlet hose to the fuel suction tube with pump and gauge 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. B001LZF

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

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.

      B001LW2E01
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tube Joint
      *3 O-ring
      *4 Collar
      *a CORRECT
      *b INCORRECT

      Note


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

      • Check that the fuel tube joint is securely inserted to the end.

      • 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 pushed out.

    2. B001L9G

      Connect the fuel pump connector.

  7. CONNECT CABLE TO NEGATIVE AUXILIARY 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. B001KP5

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

  10. INSTALL REAR SEAT CUSHION LOCK HOOK

    Click here

  11. INSTALL REAR SEAT CUSHION ASSEMBLY

    Click here

  12. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE

    Click here

  13. INSTALL DECK FLOOR BOX RH

    Click here

  14. INSTALL REAR NO. 3 FLOOR BOARD

    Click here

  15. INSTALL REAR DECK FLOOR BOX

    Click here

  16. INSTALL REAR NO. 2 FLOOR BOARD

    Click here