FUEL PUMP INSTALLATION


  1. INSTALL FUEL TANK SUCTION TUBE GASKET


    1. Install a new gasket to the fuel tank.

  2. INSTALL FUEL SUCTION TUBE ASSEMBLY


    1. Line up the pipe and connector and push them together until a "click" sound is heard.

      Note


      • Check that there are no scratches or foreign objects on the connecting part.

      • After connecting the pipe and connector, check that the pipe and connector are securely connected by pulling on them.

    2. Install the fuel suction tube assembly to the fuel tank.

  3. INSTALL FUEL PUMP GAUGE RETAINER


    1. A011B9NE02
      Text in Illustration
      *a Cutout

      Align the protrusion of the fuel suction tube assembly with the cutouts of the fuel tank.

      Note

      Ensure that the fuel suction tube gasket is in the correct position.

    2. While holding the fuel suction tube assembly by hand, position the fuel pump gauge retainer and tighten it lightly by hand.

      Note

      Check that the contact surface of the fuel tank retainer is not scratched or damaged and prevent the entry of foreign objects.

    3. A011912E01

      Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer.

      SST
      09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

      Note

      Do not use any tools other than SST.

      Tech Tips


      • Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.

      • Align the ribs of the fuel pump gauge retainer with the tips of SST.

    4. A011A0SE02
      Text in Illustration
      *1 Starting Point
      *2 Lock Point
      *a Front of Vehicle
      *b Hold
      *c Turn

      Using SST, align the marks on the fuel tank and fuel pump gauge retainer.

      SST
      09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

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


    1. A0118IOE02
      Text in Illustration
      *1 Retainer
      *2 O-Ring
      *3 Fuel Tube Connector
      *4 Fuel Pipe
      *a Push

      Connect the No. 1 fuel evaporation tube to the fuel suction tube assembly and lock it by pushing in the retainer.

      Note


      • Check that there are no scratches or foreign objects on the connecting part.

      • Check that the No. 1 fuel evaporation tube is inserted securely.

      • After installing the retainer, check that the No. 1 fuel evaporation tube is securely connected by pulling on it.

  5. CONNECT FUEL TANK WIRE


    1. Connect the fuel tank wire connector to the fuel suction tube assembly.

      Note

      After connecting the fuel tank wire connector, check that the fuel tank wire is inserted securely.

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0117WAE02
      Text in Illustration
      *1 Fuel Tube Connector
      *2 Tube Joint Clip
      *3 O-Ring
      *a OK
      *b NG

      Insert the fuel tank main tube into the fuel suction tube assembly plug and lock it with the tube joint clip.

      Note


      • Check that there are no scratches or foreign objects on the connecting part.

      • Check that the fuel tank main tube is inserted securely.

      • Check that the tube joint clip is on the collar of the main tube.

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

  7. INSTALL FUEL TANK ASSEMBLY


    1. Clean and degrease the bolt holes.

    2. Set the fuel tank and 2 fuel tank bands on the engine lifter.

    3. Slowly raise the engine lifter and install the fuel tank onto the vehicle.

      Note

      Make sure that the fuel tank does not fall.

    4. A011BM1E01

      Tighten the 4 bolts in the sequence shown in the illustration, and secure the 2 fuel tank bands and the fuel tank.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  8. CONNECT REAR FUEL EMISSION TUBE SUB-ASSEMBLY


    1. A011BLBE02
      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 Fuel Pipe
      *4 O-Ring
      *a Push

      Connect the rear fuel emission tube and lock it by pushing in the retainer.

      Note


      • Check that there are no scratches or foreign objects on the connecting part.

      • Check that the rear fuel tank emission tube is inserted securely.

      • After installing the retainer, check that the rear fuel emission tube is securely connected by pulling on it.

  9. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0117O9E03
      Text in Illustration
      *1 Retainer
      *2 Checker
      *3 Fuel Pipe
      *4 Fuel Tube Connector
      *5 O-Ring
      *a Push

      Line up the pipe and connector and push them together until a "click" sound is heard.

    2. Push the checker in to lock it.

      Note


      • Check that there are no scratches or foreign objects on the connecting part.

      • Check that the fuel tank main tube is inserted securely.

      • After installing the checker, check that the fuel tank main tube is securely connected by pulling on it.

  10. CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY


    1. A0119UEE02
      Text in Illustration
      *1 Retainer
      *a Push

      Connect the inlet tube to the fuel tank assembly and lock it by pushing in the retainer.

      Note


      • Check that there are no scratches or foreign objects on the connecting part.

      • Check that the inlet tube is inserted securely.

      • After installing the retainer, check that the inlet tube is securely connected by pulling on it.

      Tech Tips


      • Insert the inlet tube until a "click" sound is heard.

      • The quick connector cannot be locked when the tube is not inserted securely.

    2. A011748E02
      Text in Illustration
      *1 Retainer
      *a Push

      Connect the fuel tank breather tube to the fuel tank assembly and lock it by pushing in the retainer.

      Note


      • Check that there are no scratches or foreign objects on the connecting part.

      • Check that the breather tube is inserted securely.

      • After installing the retainer, check that the breather tube is securely connected by pulling on it.

      Tech Tips

      The quick connector cannot be locked when the tube is not inserted securely.

  11. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A01178LE01
      Text in Illustration
      *1 Yellow mark

      Connect the No. 1 charcoal canister outlet hose.

      Note


      • Install the No. 1 charcoal canister outlet hose with its yellow mark toward the rear of the vehicle.

      • After connecting the fuel tank breather tube and No. 1 charcoal canister outlet hose, check that the evaporation vent tube clamp is securely connected by pulling on it.

  12. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. Engage the claw and install the No. 1 fuel tank protector with the 2 clips and 4 nuts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  13. CONNECT FUEL TANK WIRE


    1. Pull the fuel tank wire through the floor, install the grommet in the floor, and connect the fuel tank wire connector.

  14. ADD FUEL


    1. Open the fuel tank cap to add fuel.

  15. 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 main switch on.

        Note

        Do not start the engine.

      3. Enter the following menus: Powertrain / Engine and ECT / 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 for fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts if necessary.

    3. Turn the ignition switch off.

    4. Disconnect the intelligent tester from the DLC3.