FUEL PUMP INSTALLATION

PROCEDURE


  1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. A00322TC06
      *1 Fuel Suction Tube Set Gasket

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

    2. A003217C02
      *a Notch
      *b Protrusion

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

      Note

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

    3. Align the protrusions of the fuel suction tube with pump and gauge assembly with the notches of the fuel tank assembly.

  2. INSTALL FUEL PUMP GAUGE RETAINER


    1. A00323PC01
      *a

      Start Mark

      (Fuel Tank Assembly Side)
      *b

      Start Mark

      (Fuel Pump Gauge Retainer Side)
      *c Front Side

      While holding the fuel suction tube with pump and gauge assembly by hand to prevent it from tilting, align the start marks on a new fuel pump gauge retainer and the fuel tank assembly and tighten the fuel pump gauge retainer 180° by hand.

      Tech Tips

      Check that there is no damage, dent, foreign matter, or other defect on the threads of the fuel tank assembly.

    2. A003225C02
      *a SST (Plate)
      *b SST (Claw)
      *c SST (Bolt)
      *d Rib

      Temporarily install SST (plate and claws) to the fuel pump gauge retainer.

      SST
      09808-14030   ( 09808-01030, 09808-01040, 09808-01050 )

      Tech Tips

      Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.

    3. While pressing SST (claws) against the fuel pump gauge retainer ribs securely, tighten SST (bolts).

      Tech Tips

      Install SST while pressing SST (claws) toward the fuel pump gauge retainer (towards the center of SST).

    4. Install SST (handle).

    5. A003247C02
      *a SST (Plate)
      *b SST (Handle)
      *c SST (Claw)
      *d Mark
      *e Front Side

      Tighten the fuel pump gauge retainer approximately 270° from the start mark on the fuel tank assembly so that the start mark on the fuel pump gauge retainer comes within the range shown in the illustration.

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

      Note


      • Do not use any tools other than specified in this operation as this may result in damage to the fuel pump gauge retainer or the fuel tank assembly.

      • Do not press down on SST excessively as this may make the retainer hard to rotate, and may damage components.

      • Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.

      • Do not spin SST too fast or use an impact wrench as this may result in damage to components.

      • If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.

      Tech Tips


      • Fit the notch of SST on the rib of the fuel pump gauge retainer.

      • Lightly press down on SST to prevent it from separating from the retainer. While pressing SST, rotate SST (handle) slowly to tighten the retainer.

      • The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

  3. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. Connect the No. 1 charcoal canister outlet hose to the fuel suction tube assembly.

      Tech Tips

      After connecting the No. 1 fuel tank evaporation tube and No. 1 charcoal canister outlet hose, check that the No. 1 fuel tank evaporation tube is positioned below the No. 1 charcoal canister outlet hose.

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


    1. Connect the No. 1 fuel evaporation tube sub-assembly to the fuel suction tube assembly with the clip.

  5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Push the fuel tube joint onto the plug of the fuel suction plate, then install the tube joint clip.

      A00324VC02
      *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 plug is securely inserted to the end of the fuel tube joint.

      • 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. Connect the fuel pump connector.

  6. 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

  7. INSPECT FOR FUEL LEAK

    Click here

  8. INSTALL REAR FLOOR SERVICE HOLE COVER


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

  9. INSTALL REAR SEAT ASSEMBLY

    Click here

  10. INSTALL BATTERY BOX COVER

    Click here