FUEL PUMP INSTALLATION

PROCEDURE


  1. INSTALL FUEL SENDER GAUGE ASSEMBLY

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  2. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. A002ZZYC05
      *1 Fuel Suction Tube Set Gasket

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

    2. A002ZUDC01
      *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. A0030XNC01
      *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.

  3. INSTALL FUEL PUMP GAUGE RETAINER


    1. Install SST to a new fuel pump gauge retainer.


      1. A00316CC01
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw)
        *b SST (Plate)
        *c SST (Bolt)
        *d Narrow
        *e Wide
        *f Correct
        *g Incorrect

        Temporarily install SST (plate), SST (claw) and SST (bolt) to the fuel pump gauge retainer.

        SST
        09808-14030   ( 09808-01020, 09808-01030, 09808-01050 )
        09808-01071

        Note


        • Install SST (claw) to the correct location.

        • Do not install SST (claw) to a location where the pitch between ribs of the fuel pump gauge retainer is narrow.

      2. A00307MC01
        *a Center Point of Fuel Pump Gauge Retainer

        Adjust the position of SST (claw) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.

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

    2. A002ZT8C01
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d Front
      *e Press down
      *f Start of Threads of the Fuel Pump Gauge Retainer
      *g Copy of Start of Threads Mark
      *h Align

      While pressing down on the fuel suction tube with pump and gauge assembly, have another person align the start of the threads of the fuel pump gauge retainer with the start of threads mark that was copied onto the vehicle body.

    3. A0030G5C01
      *1 Fuel Pump Gauge Retainer
      *2 Fuel Tank Assembly
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d Front
      *e Tighten approximately 90°
      *f Fuel pump gauge retainer rises up
      *g Press quickly and firmly
      *h Cross Section
      *i Paint Mark

      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°.

    4. 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.

      Note


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

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

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

      • If SST slips off of the fuel pump gauge retainer, loosen SST (bolt) and install SST again.

      • Do not turn the fuel pump gauge retainer if the paint marks become misaligned.

      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.

    5. A003146C01
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d One Person in Charge of Tightening
      *e One Person in Charge of Pressing Down
      *f Front
      *g Approximately 180°

      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°.

    6. A00317DC01
      *a Front
      *b Measurement Position
      *c Vernier Caliper
      *d A-A Cross Section

      Check the tightening status of the fuel pump gauge retainer.


      1. 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.

    7. A002ZQIC01
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d SST (Handle)
      *e One Person in Charge of Tightening
      *f One Person in Charge of Pressing Down
      *g Approximately 90°
      *h Front

      Install SST (handle) to SST (plate).

      SST
      09808-14030   ( 09808-01010, 09808-01020, 09808-01030, 09808-01050 )
      09808-01071

    8. 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 90°.

    9. A00312JC01
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d SST (Handle)
      *e Press down
      *f Pull
      *g Start of Threads of the Fuel Pump Gauge Retainer
      *h Copy of Fully Tightened Mark
      *i Front

      While pressing down on the center of SST (handle) to prevent SST from separating from the fuel pump gauge retainer, pull SST (handle) with another person pulling the opposite end of SST (handle), and slowly tighten the fuel pump gauge retainer until it reaches the fully tightened mark that was copied onto the vehicle body.

  4. INSTALL TANK SUCTION TUBE SUPPORT


    1. Engage the 2 claws to install the tank suction tube support.

    2. A0031AXC01
      A0030PX Push

      Install the fuel tank evaporation vent tube sub-assembly.

      Note

      Securely install the fuel tank evaporation vent tube sub-assembly by pushing it until it makes a "click" sound.

  5. CONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (w/ Combustion Type Power Heater)


    1. A002ZNSC01
      *1 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-ring
      *c Collar
      *d Correct
      *e Incorrect

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

      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 No. 2 fuel main tube sub-assembly is securely connected by pulling on it.

  6. 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.

      A002ZZRC01
      *A w/o Combustion Type Power Heater *B w/ Combustion Type Power Heater
      *1 Tube Joint Clip - -
      *a Fuel Tube Joint *b O-ring
      *c Collar *d Correct
      *e Incorrect - -

      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.

  7. CONNECT FUEL RETURN 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.

      A0030JEC01
      *A w/o Combustion Type Power Heater *B w/ Combustion Type Power Heater
      *1 Tube Joint Clip - -
      *a Fuel Tube Joint *b O-ring
      *c Collar *d Correct
      *e Incorrect - -

      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 return tube sub-assembly is securely connected by pulling on it.

  8. CHECK AIRTIGHTNESS


    1. A00317WC01
      *a Air

      After installing the fuel suction tube with pump and gauge assembly, check for fuel leaks by first applying soapy water to the area where the fuel suction tube with pump and gauge assembly and fuel pump gauge retainer contact, and then blow forcefully into the fuel inlet area through a flexible pouring spout or similar tube.

    2. Blow forcefully until the reverse flow prevention valve inside the fuel inlet activates.

      CAUTION:

      Be careful not to inhale any fuel vapor.

      Tech Tips

      There should be a faintly audible sound when the reverse flow prevention valve operates.

    3. 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.

  9. INSPECT FOR FUEL LEAK

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  10. 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.

    5. Connect the 2 connectors.

  11. INSTALL REAR SEAT CUSHION ASSEMBLY

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