FUEL PUMP INSTALLATION

PROCEDURE


  1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B001N74E05
      Text in Illustration
      *1 Fuel Suction Tube Set Gasket

      Install a new fuel suction tube set gasket to the fuel tank assembly.

    2. B001KKBE06
      Text in Illustration
      *a Notch
      *b Protrusion

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

      Note

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

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

    4. B001L9KE01
      Text in Illustration
      *a Paint Mark

      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.

  2. INSTALL FUEL PUMP GAUGE RETAINER


    1. B001LY5E02
      Text in Illustration
      *a Copy of Start of Threads Mark
      *b Start of Threads of the Fuel Pump Gauge Retainer
      *c Align
      B001KHV Press down
      B001NB3 Front

      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. B001N6EE02
        Text in Illustration
        *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, 09808-01090, 09808-01100 )
      2. B001LDZE02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        B001KHV Push
        B001NB3 SST (Bolt)

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

      3. B001L9FE02
        Text in Illustration
        *a SST (Plate)
        *b SST (Claw Set)
        B001KHV SST (Bolt)

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

        SST
        09808-14031   ( 09808-01030, 09808-01090 )
      4. B001M6OE01
        Text in Illustration
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        B001KHV Front

        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. B001M50E02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        B001KHV Press

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

    3. B001MRBE02
      Text in Illustration
      *1 Fuel Pump Gauge Retainer
      *2 Fuel Tank Assembly
      *a SST (Plate)
      *b Tighten approximately 90°
      *c Fuel pump gauge retainer rises up
      *d Cross Section
      *e Paint Mark
      B001KHV Press quickly and firmly
      B001NB3 Front

      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 90°.

      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.


      1. Quickly and firmly press down on the part of the fuel pump gauge retainer closest to the rear 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.

    4. B001M7GE02
      Text in Illustration
      *a SST (Plate)
      *b One Person in Charge of Tightening
      *c One Person in Charge of Pressing Down
      *d Approximately 180°
      B001KHV Front

      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 180°.

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


      1. B001LLPE02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Assembly
        *a Measurement Position
        *b Vernier Caliper
        B001NB3 Front

        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.

    6. B001M5GE02
      Text in Illustration
      *a SST (Handle)
      *b SST (Plate)
      *c One Person in Charge of Tightening
      *d One Person in Charge of Pressing Down
      *e Approximately 180°
      B001KHV Front

      Install SST (handle) to SST (plate).

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

    7. 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 180°.

    8. B001LSDE02
      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
      B001KHV Tighten
      B001NB3 Front

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

  3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Push the fuel tube joint onto the plug of the fuel suction plate sub-assembly, then install the tube joint clip.

      B001KGIE01
      Text in Illustration
      *1 Fuel Suction Plate Sub-assembly *2 Tube Joint Clip
      *3 Fuel Tank Main Tube Sub-assembly - -
      *a O-ring *b Correct
      *c Incorrect *d Collar
      *e Fuel Tube Joint - -
      B001KHV Insert B001NB3 Insert

      Note


      • Check that there are no scratches or foreign matter around the connecting parts 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 as shown in the illustration.

      • After installing the tube joint clip, check that the fuel tank main tube sub-assembly is securely connected by pulling on it.

  4. CHECK AIRTIGHTNESS


    1. B001L6NE01
      Text in Illustration
      *a Soapy Water Application Area

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

    2. B001MESE02
      Text in Illustration
      *a Vacuum Pump
      *b Port (A)

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

    3. B001MI0E02
      Text in Illustration
      *a Port (A)
      *b Port (B)
      *c Port (C)
      *d Vacuum Pump

      Close port (B), port (C) and use the vacuum pump to apply 5 kPa (0.1 kgf/cm2, 0.7 psi) of compressed air to port (A) 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.

  5. CONNECT FUEL TANK EVAPORATION TUBE


    1. B001N2TE05
      Text in Illustration
      *a Retainer

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

  6. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


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

      Tech Tips

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

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


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

  8. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.

    2. Clean the installation surfaces of the rear floor service hole cover and vehicle body.

    3. Connect the fuel pump connector.

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

  9. 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.

  10. INSPECT FOR FUEL LEAK

    Click here

  11. INSTALL REAR SEAT CUSHION LOCK HOOK

    Click here

  12. INSTALL REAR SEAT CUSHION ASSEMBLY

    Click here

  13. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE

    Click here

  14. INSTALL DECK FLOOR BOX RH

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  15. INSTALL REAR NO. 3 FLOOR BOARD

    Click here

  16. INSTALL REAR DECK FLOOR BOX

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  17. INSTALL REAR NO. 2 FLOOR BOARD

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