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

      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. A0031XMC02
      *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.

  2. INSTALL FUEL PUMP GAUGE RETAINER


    1. A00324KC02
      *a Copy of Start of Threads Mark
      *b Start of Threads of the Fuel Pump Gauge Retainer
      *c Align
      A00328E Press down
      A00320Y Front

      Align the start of the threads of a new fuel pump gauge retainer with the start of threads mark that was copied onto the vehicle body and while pushing down the fuel suction tube with pump and gauge assembly, attach the fuel pump gauge retainer.

    2. Install SST to the fuel pump gauge retainer.


      1. A003215C02
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Protrusion
        *c Notch
        *d Do not install SST (Claw Set)

        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 install SST (claw set) to the start of threads location of the fuel pump gauge retainer.

      2. A0031Y2C02
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        A00328E Push
        A00320Y SST (Bolt)

        Push SST (claw set) against the fuel pump gauge retainer and tighten SST (bolt).

      3. A00329TC02
        *a SST (Plate)
        *b SST (Claw Set)
        A00328E SST (Bolt)

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

        SST
        09808-14031   ( 09808-01030, 09808-01090 )
      4. A00320JC04
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        A00328E Front

        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. A0031YTC02
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        A00328E Press

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

    3. A003266C02
      *1 Fuel Pump Gauge Retainer
      *2 Fuel Tank Assembly
      *a SST (Plate)
      *b Tighten approximately 90°
      *c Fuel pump gauge retainer rises up
      *d Cross Section
      *e Paint Mark
      A00328E Press quickly and firmly
      A00320Y Front

      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°.

      Note


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

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

    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.

      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. A00327AC02
      *a SST (Plate)
      *b One Person in Charge of Tightening
      *c One Person in Charge of Pressing Down
      *d Approximately 180°
      A00328E Front

      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. Check the tightening status of the fuel pump gauge retainer.


      1. A003249C02
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Assembly
        *a Measurement Position
        *b Vernier Caliper
        A00320Y Front

        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. A003206C02
      *a SST (Handle)
      *b SST (Plate)
      *c One Person in Charge of Tightening
      *d One Person in Charge of Pressing Down
      *e Approximately 90°
      A00328E Front

      Install SST (handle) to SST (plate).

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

    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. A0031YQC02
      *a SST (Handle)
      *b SST (Plate)
      *c Copy of Fully Tightened Mark
      *d Start of Threads of the Fuel Pump Gauge Retainer
      A00328E Tighten
      A00320Y Front

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

  3. 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.

      A00326HC03
      *1 Fuel Suction Plate Sub-assembly *2 Tube Joint Clip
      *3 Fuel Tank Main Tube Sub-assembly - -
      *a O-ring *b Correct
      *c Incorrect *d Collar
      *e Fuel Tube Joint - -
      A00328E Insert A00320Y Insert

      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.

  4. CHECK AIRTIGHTNESS


    1. A0031Y8C02
      *a Soapy Water Application Area

      Apply soapy water to the contact areas between the fuel suction tube with pump and gauge assembly and fuel pump gauge retainer.

      Note

      Cover the connector of the fuel suction tube with pump and gauge assembly with protective tape.

    2. A0031XOC02
      *a Vacuum Pump
      *b Port (A)

      Install a vacuum pump to the port (A) of the fuel suction tube with pump and gauge assembly as shown in the illustration.

    3. A0032A2C02
      *a Port (A)
      *b Port (B)
      *c Vacuum Pump

      Close the port (B) and using the vacuum pump, apply 5 kPa (0.1 kgf/cm2, 0.7 psi) of compressed air to the port (A) as shown in the illustration.

      Note

      Do not apply more compressed air than necessary.

    4. 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.

  5. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. Connect the No. 1 charcoal canister outlet hose to the fuel suction tube with pump and gauge assembly.

      Tech Tips

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

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


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

  7. 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

  8. INSPECT FOR FUEL LEAK

    Click here

  9. 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.

  10. INSTALL REAR SEAT ASSEMBLY


  11. INSTALL BATTERY BOX COVER