FUEL PUMP INSTALLATION

PROCEDURE


  1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


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

    2. Connect the fuel return vent tube sub-assembly and set the fuel suction tube with pump and gauge assembly into the fuel tank assembly.

      Note


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

      • Do not damage the fuel return vent tube sub-assembly.

      • When connecting the fuel tube connector, do not excessively pull on the fuel return vent tube sub-assembly.

    3. B0075B1C02
      *a Protrusion
      B0073AQ Notch

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

  2. INSTALL FUEL PUMP GAUGE RETAINER


    1. While pressing down on the fuel suction tube with pump and gauge assembly, temporarily install the fuel pump gauge retainer.

    2. B007405C13
      *a Insertion Point
      *b SST (Plate)
      *c SST (Claw)
      *d SST (Bolt)

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

      SST
      09808-14031   ( 09808-01030, 09808-01040, 09808-01050 )

      Tech Tips

      Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

    3. While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

    4. B0073LEC04
      *a Protrusion
      *b Groove
      *c SST (Handle)
      *d SST (Plate)
      *e SST (Claw)
      *f SST (Bolt)
      B0077IM Front Side

      Install SST (handle) to SST (plate).

      SST
      09808-14031   ( 09808-01010, 09808-01030, 09808-01040, 09808-01050 )

    5. Using SST, rotate the fuel pump gauge retainer so that the protrusions of the fuel pump gauge retainer are aligned with the grooves in the fuel tank assembly to install the fuel suction tube with pump and gauge assembly to 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 press down on SST excessively as this may make the fuel pump gauge 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 (bolt) and reinstall SST.

      • Make sure that the fuel suction tube set gasket does not come off.

    6. Install the No. 1 fuel tube clamp.

  3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B0077U1C02
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *3 Fuel Tank Main Tube Sub-assembly
      *a Fuel Tube Joint
      *b O-ring
      *c Correct
      *d Incorrect
      *e Collar

      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.

  4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  5. INSPECT FOR FUEL LEAK

    Click here

  6. 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 2 fuel pump connectors.

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

  7. INSTALL REAR SEAT CUSHION LOCK HOOK

    Click here

  8. INSTALL REAR SEAT CUSHION ASSEMBLY

    Click here

  9. PERFORM INITIALIZATION


    1. Perform "Inspection After Repair" after replacing the fuel pump.