FUEL PUMP INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

   Tech Tips

   Perform "Inspection After Repairs" after replacing the fuel pump Click here.

   
   

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

   2. Connect the fuel return vent tube sub-assembly and set the fuel suction tube assembly with pump and gauge into the fuel tank assembly.

      Note

      
      

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

      • When connecting the fuel tube connector, do not forcibly pull the fuel return vent tube sub-assembly.

   3. 

      Text in Illustration

      *1	Protrusion
      	Hole

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

   4. While pressing down on the fuel suction tube assembly with pump and gauge, temporarily install the fuel pump gauge retainer.

   5. 

      Text in Illustration

      *a	Insertion Point
      	SST (Bolt)

      Set the 2 claws, 2 bolts and plate of SST on the fuel pump gauge retainer.

      SST

      09808-14031   ( 09808-01010, 09808-01020, 09808-01030, 09808-01090 )

      09808-01071

      Tech Tips

      Securely insert the ends of SST into the insertion points in the fuel pump gauge retainer.

   6. While firmly pressing the claws of SST into the insertion points in the fuel pump gauge retainer, tighten the bolts of the claws.

   7. Attach the handle of SST.

   8. 

      Text in Illustration

      *a	Protrusion
      *b	Groove
      	Front of Vehicle

      Check once more that the tip of SST is securely inserted into the insertion area of the fuel pump gauge retainer as shown in the illustration.

   9. Using SST, rotate the fuel pump gauge retainer so that the protrusions of the retainer are aligned with the grooves in the fuel tank assembly to install the fuel suction tube assembly with pump and gauge to the fuel tank assembly.

      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 pump gauge retainer will place excessive force on the fuel suction tube assembly with pump and gauge and be difficult to remove, and parts may be damaged.

      • Be sure to keep the handle level when turning it, as SST may slip off the retainer if the handle is turned at an angle with excessive force.

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

      • If SST slips off the retainer, loosen the bolts and reattach SST to the retainer.

      • Make sure that the fuel suction tube set gasket does not come off.

   10. Install the No. 1 fuel tube clamp.

   11. 

       Text in Illustration

       *1	Fuel Tube Joint
       *2	Tube Joint Clip
       *3	O-Ring
       *4	Fuel Suction Plate Sub-assembly
       *5	Collar
       *a	CORRECT
       *b	INCORRECT

       Insert the fuel tank main tube sub-assembly and fuel tank return tube into the plugs of the fuel suction plate sub-assembly and fix them in place with the 2 tube joint clips.

       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 clips are on the collars of the fuel tube joints.

       • After installing the tube joint clips, check that the fuel tube joints have not been pulled off.

       • Be careful not to damage any clips. If a clip is damaged, replace it.

   12. Connect the fuel suction tube connector.

2. 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.

3. INSPECT FOR FUEL LEAK

   Click here

4. INSTALL REAR FLOOR SERVICE HOLE COVER

   
   

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

5. INSTALL NO. 3 ROOM PARTITION PAD

   
   

   1. Install the No. 3 room partition pad with the clip.

6. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY

   Click here