FUEL PUMP

INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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

*b Notch

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.

Tech Tips

Align the protrusion of the fuel suction tube with pump and gauge assembly with the notch of the tank suction tube support.

INSTALL FUEL PUMP GAUGE RETAINER

*a "S" Mark

*b Triangle Mark

Align the triangle mark on a new fuel pump gauge retainer with the "S" mark on the fuel tank assembly and while pushing down the fuel suction tube with pump and gauge assembly, attach the fuel pump gauge retainer.

Install SST (fuel pump retainer tool assy) to the fuel pump gauge retainer.

Insert 2 SST (claw) between the service hole and fuel pump gauge retainer, and adjust the position so that the protrusions of the fuel pump gauge retainer are aligned with the grooves of SST (claw) as shown in the illustration.

*a	SST (Claw)	*b	Triangle Mark
*c	Protrusion of Fuel Pump Gauge Retainer	*d	Groove of SST (Claw)
*e	Correct	*f	Incorrect

SST: 09808-14040 ( 09882-14040 )

Note

Ensure that SST (claw) does not cover the triangle mark of the fuel pump gauge retainer.

*a	SST (Claw)
*b	SST (Plate)
*c	SST (Bolt and Washer Set)

While ensuring that SST (plate) is centered, install SST (plate) to 2 SST (claw) with 2 SST (bolt and washer set).

SST: 09808-14040 ( 09881-14040, 09883-14040 )

*a	SST (Fuel Pump Retainer Tool Assy)
*b	Triangle Mark
*c	"SERVICE" Range

While lightly pushing down on SST (fuel pump retainer tool assy), tighten the fuel pump gauge retainer by 1 and a half turns so that the triangle mark on the fuel pump gauge retainer is positioned between the "SERVICE" range on the fuel tank assembly.

Note

Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.
Do not push down on SST (fuel pump retainer tool assy) excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
Make sure to turn the breaker bar horizontally. If it is turned at an angle, SST (fuel pump retainer tool assy) may come off.
Do not spin SST (fuel pump retainer tool assy) too fast or use an impact wrench as this may damage components.
If SST (fuel pump retainer tool assy) comes off of the fuel pump gauge retainer, loosen SST (bolt and washer set) and reinstall SST (fuel pump retainer tool assy).

Tech Tips

While pushing down on SST (fuel pump retainer tool assy), turn the fuel pump gauge retainer clockwise to tighten. Make sure that the detent of the tank suction tube support does not move out of the groove of the fuel tank assembly.

CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

*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.
After installing the tube joint clip, check that the fuel tank main tube sub-assembly is securely connected by pulling on it.

CHECK AIRTIGHTNESS

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 plate sub-assembly and fuel pump gauge retainer contact, and then blow forcefully into the fuel inlet area through a flexible pouring spout or similar tube.
Blow forcefully until the reverse flow prevention valve inside the fuel inlet activates.

Note

Be careful not to inhale any fuel vapor.

Tech Tips

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

If improper installation of the fuel suction tube with pump and gauge assembly, etc. has resulted in a condition where fuel will leak, air will leak out as shown in the illustration.

Note

If air leaks out, recheck the installation condition, and replace the fuel pump gauge retainer and fuel suction tube set gasket with new ones. Also, make sure to fully wipe away the soapy water. (Any remaining soapy water can cause the fuel suction tube set gasket to slip and result in an improper seal.)

INSTALL REAR FLOOR SERVICE HOLE COVER

Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.
Clean the installation surfaces of the rear floor service hole cover and vehicle body.
Connect the 2 fuel pump connectors.
*a Butyl Tape Adhesion Area

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

Note

Securely install the rear floor service hole cover.
Return the front floor carpet to its original position.

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

*a	Protrusion
*b	Notch

FUEL PUMP INSTALLATION