FUEL PUMP INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. INSPECT FITTING OF FUEL PUMP GAUGE RETAINER


    1. Inspect the fuel pump gauge retainer.


      1. Install the fuel pump gauge retainer to the fuel tank by hand with the fuel suction with pump disconnected.


        • If the fuel pump gauge retainer can be turned 180° or more by hand, reuse the retainer.

        • If the fuel pump gauge retainer cannot be turned 180° or more by hand, replace it with a new one.

        Tech Tips

        Check that there is no damage, dents, foreign matter, or other defects on the threads of the fuel tank.

  2. INSTALL FUEL SUCTION WITH PUMP ASSEMBLY


    1. A002O8JC03
      *1 New Gasket

      Install a new gasket onto the fuel tank.

    2. A002OVNC01
      *1 Notch
      *2 Protrusion

      Set the fuel suction with pump to the fuel tank.

      Note

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

    3. Align the protrusion of the fuel suction with pump with the notch of the fuel tank.

  3. INSTALL FUEL PUMP GAUGE RETAINER


    1. A002MUZC01
      *a Co-rotation Prevention Check Mark
      A002OPC Front Side of Vehicle

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

      Tech Tips

      Perform this step only when replacing the fuel suction with pump and gauge tube assembly.

    2. A002MCOC01
      *a Start Mark (Fuel Tank Assembly)
      *b Start Mark (Fuel Pump Gauge Retainer)
      A002OPC Front Side of Vehicle

      Put the fuel pump gauge retainer on the fuel tank assembly. While holding the fuel suction with pump and gauge tube assembly, tighten the fuel pump gauge retainer one complete turn by hand.

      Note

      Replace the fuel pump gauge retainer with a new one if not installed properly.

      Tech Tips

      Make sure the start marks on the fuel pump gauge retainer and fuel tank assembly are aligned, and then tighten the fuel pump gauge retainer.

    3. A002NEMC01
      *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)

      Install SST to the fuel pump gauge retainer.


      1. Set 4 SST (claw set) to the fuel pump gauge retainer.

        SST
        09808-14031   ( 09808-01080, 09808-01090, 09808-01100 )

        Note


        • Align the notch of SST (claw set) with the protrusion 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.

      2. A002OXSC01
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        A002OPC Press
        A002ODU SST (Bolt)

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

      3. A002MM5C01
        *a SST (Plate)
        *b SST (Claw Set)
        A002OPC SST (Bolt)

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

        SST
        09808-14031   ( 09808-01030, 09808-01090 )
      4. A002OTQC01
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        A002OPC Front Side of Vehicle

        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. A002Q9KC01
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        A002OPC Press

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

    4. A002NLYC01
      *a SST (Plate)
      *b Start Mark (Fuel Pump Gauge Retainer)
      *c Worker A
      *d Worker B
      *e Approximately 180°
      *f Co-rotation Prevention Check Mark
      A002OPC Press Down
      A002ODU Slowly Rotate
      A002PA0 Front Side of Vehicle

      While one person presses down to prevent the fuel pump gauge retainer and the fuel suction with pump and gauge tube assembly from rotating together, the other person should firmly press the fuel pump gauge retainer against the threads of the fuel tank assembly, and tighten it by rotating it approximately 180°.

      CAUTION:

      Make sure not to pinch your hands with SST.

      Note


      • Be careful not to apply excessive downward force to SST, as this may damage the fuel suction with pump and gauge tube assembly or fuel tank assembly.

      • Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so make sure SST is horizontal when turning it.

      • To prevent damage to parts, do not turn SST too vigorously.

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

    5. As shown in the illustration, quickly and firmly press down on the part of the fuel pump gauge retainer closest to the front side of the vehicle so that it no longer rises up.

      A002LIGC01
      *1 Fuel Pump Gauge Retainer *2 Fuel Tank Assembly
      *a SST (Plate) *b Press Quickly and Firmly
      *c Fuel Pump Gauge Retainer Rise Up Area *d Front Side of Vehicle

      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 pressing down the fuel pump gauge retainer, there will be a sound or feeling of parts contacting and pressing together when the fuel pump gauge retainer is fully pressed down, and at this point it will stop rising up.

    6. A002OXLC01
      *a SST (Plate)
      *b Start Mark (Fuel Pump Gauge Retainer)
      *c Start Mark (Fuel Tank Assembly)
      *d Worker A
      *e Worker B
      *f Rotate to Start Mark on Fuel Tank Assembly
      A002OPC Press Down
      A002ODU Slowly Rotate
      A002PA0 Front Side of Vehicle

      While one person presses down to prevent the fuel pump gauge retainer and the fuel suction with pump and gauge tube assembly from rotating together, the other person should slowly rotate SST (plate) and tighten the fuel pump gauge retainer until it reaches the start mark on the fuel tank assembly.

      CAUTION:

      Make sure not to pinch your hands with SST.

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


      1. A002QMSC01
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Assembly
        *a Measurement Location
        *b Vernier Caliper
        A002OPC Front Side of Vehicle

        Using a vernier caliper, measure the upper surface of the fuel tank assembly in the 3 locations shown in the illustration.

        Specification
        Difference between the 3 measured values is within 3.0 mm (0.118 in.).

        Note

        If the difference between measurements is approximately 6.0 mm (0.236 in.), the threads are cross-threaded by one row (6.0 mm (0.236 in.)), so remove and reinstall the fuel pump gauge retainer.

    8. A002MJYC01
      *a SST (Handle)
      *b SST (Plate)
      *c Start Mark (Fuel Pump Gauge Retainer)
      *d Worker A
      *e Worker B
      *f Approximately 90°
      A002OPC Press Down
      A002ODU Slowly Rotate
      A002PA0 Front Side of Vehicle

      Install SST (handle) to SST (plate).

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

    9. While one person presses down to prevent the fuel pump gauge retainer and the fuel suction with pump and gauge tube assembly from rotating together, the other person should slowly rotate SST (handle) and tighten the fuel pump gauge retainer by approximately 90°.

      CAUTION:

      Make sure not to pinch your hands with SST.

    10. A002Q21C01
      *a SST (Handle)
      *b SST (Plate)
      *c Copy of Fully Tightened Mark
      *d Start of Threads of the Fuel Pump Gauge Retainer
      A002OPC Tighten
      A002ODU Front Side of Vehicle

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

  4. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A002PCPC01
      *a Paint Mark

      Connect the No. 1 charcoal canister outlet hose to the fuel suction with pump.

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


    1. A002LY9C01
      *a Paint Mark
      *b 120°
      *c Front Side of Vehicle

      Connect the No. 1 fuel evaporation tube to the fuel suction with pump with the clip.

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Push the fuel tube joint into the plug of the fuel suction with pump, and then install the tube joint clip.

      A002NIYC01
      *1 Fuel Tube Joint *2 Tube Joint Clip
      *3 O-Ring *a Correct
      *b Incorrect - -

      Note


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

      • Check that the fuel tube joint is securely and fully inserted.

      • 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 pulled out.

    2. A002P9M

      Connect the fuel pump connector.

  7. CONNECT CABLE TO NEGATIVE 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. A002PO9

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

  10. INSTALL REAR CENTER SEAT ASSEMBLY (w/ REAR NO. 1 SEAT)


    1. Install the center seat Click here.

  11. INSTALL REAR NO. 1 SEAT ASSEMBLY (w/ REAR NO. 1 SEAT)


    1. Install the rear No. 1 seat Click here.