FUEL PUMP (for TMMK Made) INSTALLATION


  1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B000K38E01
      Text in Illustration
      *1 Fuel Suction Tube Set Gasket
      *a Fuel Cut-off Tube
      B000K70 Push in
      B000IB9 Push

      Install a new fuel suction tube set gasket to the fuel suction tube with pump and gauge assembly.

    2. Push in the fuel cut-off tube to the fuel suction tube with pump and gauge assembly and push the retainer so that the claws engage.

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

      Note


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

      • Do not damage the tube and fuel pump harness.

  2. INSTALL FUEL TANK VENT TUBE SET PLATE


    1. B000JAAE02
      Text in Illustration
      *a Cutout
      *b Protrusion

      Align the cutout of the fuel suction tube with pump and gauge assembly and the protrusion of the fuel tank vent tube set plate.

    2. Install the fuel tank vent tube set plate with the 8 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  3. CONNECT NO. 2 CHARCOAL CANISTER OUTLET HOSE


    1. Connect the No. 2 charcoal canister outlet hose to the fuel suction tube with pump and gauge assembly and slide the clip to secure it.

  4. CONNECT FUEL EMISSION HOSE


    1. Connect the fuel emission hose to the fuel suction tube with pump and gauge assembly and slide the clip to secure it.

  5. 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.

      B000II8E03
      Text in Illustration
      *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 connected part of the fuel tube joint and pipe 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.

      • After installing the tube joint clip, check that the fuel tube joint cannot be pulled out.

  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  7. INSPECT FOR FUEL LEAK


    1. Check fuel pump operation.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON and turn the intelligent tester on.

        Note

        Do not start the engine.

      3. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.

      4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.

    2. Inspect for fuel leaks.


      1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

    3. Turn the ignition switch off.

    4. Disconnect the intelligent tester from the DLC3.

  8. 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. B000HXH

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

      Text in Illustration
      B000K33 Butyl Tape

  9. INSTALL REAR SEAT CUSHION LOCK HOOK


    1. B000HKU

      Engage the 2 claws to install a new rear seat cushion lock hook as shown in the illustration.

      Note

      Rear seat cushion lock hooks must not be reused.

      Tech Tips

      Use the same procedure for the RH side and the LH side.

  10. INSTALL REAR SEAT CUSHION ASSEMBLY


    1. Place the rear seat cushion assembly in the cabin.

      Note

      Be careful not to damage the vehicle body.

    2. Pass the 2 rear seat inner belt assemblies through the rear seat cushion assembly.

    3. B000KWO

      Engage the 2 rear seat cushion frame hooks on the front side of the rear seat cushion assembly to the 2 rear seat cushion lock hooks as shown in the illustration.

    4. Confirm that the rear seat cushion assembly is securely installed.

      Note

      When installing the rear seat cushion assembly, make sure that the seat belt buckles are not under the rear seat cushion assembly.