FUEL PUMP INSTALLATION

PROCEDURE

1. Click here

   INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

   
   

   1. Apply a light coat of gasoline or grease to a new gasket, and install it to the fuel tank.

   2. 

      *a	Protrusion
      *b	Groove
      	Front

      Install the fuel suction with pump and gauge tube into the fuel tank.

      Note:

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

      Tip:

      Align the protrusion of the fuel suction with pump and gauge tube with the groove of the fuel tank.

   3. 

      *a	Co-rotation Prevention Check Mark
      	Front

      Apply a co-rotation prevention check mark to the fuel tank vent tube assembly.

      Tip:

      Perform this procedure when replacement of the fuel tank vent tube assembly is necessary.

   4. 

      *a	Rotational Start Point Mark (Fuel Tank Assembly Side)
      *b	Rotational Start Point Mark (Fuel Pump Gauge Retainer Side)
      	Front

      Temporarily place the fuel pump gauge retainer by aligning the rotational start point mark of a new fuel pump gauge retainer with the rotational start point mark of the fuel tank assembly while pressing the fuel tank vent tube assembly into the fuel tank assembly.

   5. 

      *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)

      Set 4 SSTs (claw sets) to the fuel pump gauge retainer and temporarily install.

      09808-14031

      09808-01080

      09808-01090

      09808-01100

      Note:
      

      • Align the cutout of SST (claw set) to the rib 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.

   6. 

      *1	Fuel Pump Gauge Retainer
      *a	SST (Claw Set)
      *b	Hook
      	Press
      	SST (Bolt)

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

   7. 

      *a	SST (Plate)
      *b	SST (Claw Set)
      	SST (Bolt)

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

   8. 

      *a	Center of Fuel Pump Gauge Retainer
      *b	SST (Plate)
      	Front

      Adjust the position of SST (plate) so that the setting hole of SST (handle) aligns with the center of the fuel pump gauge retainer.

   9. 

      *1	Fuel Pump Gauge Retainer
      *a	SST (Plate)
      *b	SST (Claw Set)
      *c	SST (Bolt)
      *d	Rib
      	Press

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

   10. 

       *a	Co-rotation Prevention Check Mark
       *b	Tightening Start Position
       *c	One and Half Rotation Position
       	Front

       While one person presses the fuel tank vent tube assembly into the fuel tank assembly, have another person firmly press the fuel pump gauge retainer into the threads of the fuel tank assembly and tighten approximately one and a half turns.

       Note:
       

       • Do not use any tools other than SST, such as a screwdriver, etc.

       • Do not use excessive force when pressing down on SST, as the fuel tank vent tube assembly will place excessive force on the pump gauge retainer and be difficult to remove, and parts may be damaged.

       • Do not use an impact wrench or turn the SST handle with excessive force, as parts may be damaged.

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

   11. 

       *a	SST (Plate)
       *b	Person in Charge of Tightening
       *c	Person in Charge of Supporting
       *d	Approximately 180°
       	Front

       While one person presses the fuel tank vent tube assembly into the fuel tank assembly, have another person slowly tighten approximately 180°.

   12. Check the tightening condition of the fuel pump gauge retainer.

       
       
       1. 

          *1	Fuel Pump Gauge Retainer
          *2	Fuel Tank Assembly
          *a	Vernier Caliper
          *b	Measurement Height
          	Front
          	Measurement Position

          Using a vernier caliper, measure the upper surface dimensions of the fuel tank assembly at the 3 positions as shown in the illustration.

          Standard
          Measurement difference is within 3 mm.

          Note:

          If the measurement difference is approximately 6 mm, the threads misaligned by 1 threads (6 mm) and the fuel pump gauge retainer must be installed again.

   13. Install SST (handle) to SST (plate).

       09808-14031

       09808-01010

       09808-01020

   14. 

       *a	SST (Handle)
       *b	SST (Plate)
       *c	Tightening Complete Position
       *d	Rotational Start Point Mark of Fuel Pump Gauge Retainer
       *e	Rotational Start Point Mark of Fuel Tank Assembly
       *f	Person in Charge of Tightening
       *g	Person in Charge of Supporting
       	Tighten
       	Front

       While one person presses the fuel tank vent tube assembly onto the fuel tank assembly, have another person use SST (handle) and slowly tighten the fuel pump gauge retainer until it reaches the tightening complete position.

2. Click here

   INSTALL FUEL TANK SUB-ASSEMBLY

   (Click here)