FUEL PUMP(for Double Tank Type) INSTALLATION

PROCEDURE


  1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. Apply a light coat of diesel fuel or grease to a new gasket and install the gasket to the fuel tank sub-assembly.

    2. B001CZ8C06
      *a Protrusion
      *b Groove

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

      Note

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

      Tech Tips

      Align the cutout of the fuel suction with pump and gauge tube assembly to the groove of the fuel tank sub-assembly.

    3. B001IAWC02
      *a Co-rotation Prevention Check Mark

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

      Tech Tips

      Perform this procedure when replacement of the fuel suction with pump and gauge tube assembly is necessary.

    4. B001EJPC02
      *a Rotational Start Point Mark (Fuel Tank Sub-assembly Side)
      *b Rotational Start Point Mark (Fuel Pump Gauge Retainer Side)

      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 sub-assembly while pressing the fuel suction with pump and gauge tube assembly into the fuel tank sub-assembly.

    5. B001GAWC01
      *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.

      SST
      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. B001GYSC03
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Hook
      B001CHY Press
      B001DEF SST (Bolt)

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

    7. B001GNDC03
      *a SST (Plate)
      *b SST (Claw Set)
      B001CHY SST (Bolt)

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

    8. B001F2IC03
      *a Center of Fuel Pump Gauge Retainer
      *b SST (Plate)

      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. B001G7GC01
      *1 Fuel Pump Gauge Retainer
      *a SST (Plate)
      *b SST (Claw Set)
      *c SST (Bolt)
      *d Rib
      B001DLW Press

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

    10. B001I0HC02
      *a Co-rotation Prevention Check Mark
      *b Tightening Start Position
      *c One and Half Rotation Position

      While one person presses the fuel suction with pump and gauge tube assembly into the fuel tank sub-assembly, have another person firmly press the fuel pump gauge retainer into the threads of the fuel tank sub-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 suction with pump and gauge 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. B001HUHC02
      *a SST (Plate)
      *b Person in Charge of Tightening
      *c Person in Charge of Supporting
      *d Approximately 180°

      While one person presses the fuel suction with pump and gauge tube assembly into the fuel tank sub-assembly, have another person slowly tighten approximately 180°.

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


      1. B001GP6C02
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Sub-assembly
        *a Vernier Caliper
        *b Measurement Position
        *c Measurement Height

        Using a vernier caliper, measure the upper surface dimensions of the fuel tank sub-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. B001FUIC02
      *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 Sub-assembly
      *f Person in Charge of Tightening
      *g Person in Charge of Supporting
      B001CHY Tighten

      Install SST (handle) to SST (plate).

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

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

  2. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Install the fuel tank sub-assembly Click here.