FUEL PUMP INSTALLATION

INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY
1. Text in Illustration
  
  *1 Gasket
  
  Install a new gasket onto the fuel tank.
2. Text in Illustration
  
  *1 Notch
  
  *2 Protrusion
  
  Set the fuel suction tube with pump and gauge assembly to the fuel tank.
  
  Note
  
  Make sure that the fuel sender gauge arm does not bend.
3. Align the protrusions of the fuel suction tube assembly with pump and gauge with the notches of the fuel tank.

Text in Illustration
*1	Gasket

Text in Illustration
*1	Notch
*2	Protrusion

INSTALL FUEL PUMP GAUGE RETAINER

Text in Illustration
*1	Start Mark
*2	Mark
*3	Front Side

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

Text in Illustration
*1	SST (Plate)
*2	SST (Claw)
*3	Rib

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

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

Tech Tips

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

While pressing the claws of SST to the fuel pump gauge retainer ribs securely, tighten the bolts.

Tech Tips

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

Text in Illustration
*1	SST (Handle)
*2	SST (Plate)
*3	SST (Claw)
*4	Mark
*a	Front Side

Tighten the fuel pump gauge retainer approximately 360° so that the mark on the retainer comes within the range shown in the illustration.

SST: 09808-14030 ( 09808-01010, 09808-01020, 09808-01030, 09808-01040, 09808-01050 )

Note

Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
Do not press down on SST excessively as this may make the retainer hard to rotate, and may damage components.
Make sure to rotate the SST handle horizontally. If the SST handle 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 retainer, loosen the SST bolts and reinstall SST.

Tech Tips

Lightly press down on SST to prevent it from separating from the retainer. While pressing SST, rotate the handle slowly to tighten the retainer.
The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

CONNECT FUEL TANK EVAPORATION TUBE
1. Text in Illustration
  
  *1 Retainer
  
  Connect the fuel tank evaporation tube to the fuel suction tube assembly.
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. 2 fuel tank evaporation tube and No. 1 charcoal canister outlet hose, check that the No. 2 fuel tank evaporation tube is positioned below the No. 1 charcoal canister outlet hose.
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.

Text in Illustration
*1	Retainer

CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Text in Illustration
*1	Tube Joint Clip
*2	Fuel Tube Joint
*3	O-ring
*4	Collars
*a	CORRECT
*b	INCORRECT

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

Note

Check that there are no scratches or foreign matter around the connected part 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 cannot be pushed out.

Connect the fuel pump connector.

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.
INSPECT FOR FUEL LEAK
1. Check fuel pump operation.
  1. Connect the GTS to the DLC3.
  2. Turn the power switch on (IG).
    
    Note
    
    Do not start the engine.
  3. Turn the GTS on.
  4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
  5. 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 that there is no fuel leakage after performing maintenance anywhere on the fuel system. If there is a fuel leak, repair or replace parts as necessary.
3. Turn the power switch off.
4. Disconnect the GTS from the DLC3.
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Install the rear floor service hole cover with new butyl tape.
INSTALL REAR SEAT CUSHION ASSEMBLY
1. Place the rear seat cushion assembly in the cabin.
  
  Note
  
  Be careful not to damage the vehicle body.
2. Text in Illustration
  
  *1 Rear Hook
  
  *2 Front Hook
  
  Engage the 2 rear hooks of the rear seat cushion assembly to the rear seatback assembly.
3. Engage the 2 front hooks of the rear seat cushion assembly to the vehicle body as shown in the illustration.
4. Confirm that the rear seat cushion assembly is firmly installed.
  
  Note
  
  When installing the rear seat cushion assembly, make sure that the seat belt buckles are not under the rear seat cushion assembly.
INSTALL DECK FLOOR BOX RH
1. Engage the claw and 4 guide to install the deck floor box RH.
INSTALL REAR NO. 3 FLOOR BOARD
1. Install the rear No. 3 floor board.

Text in Illustration
*1	Rear Hook
*2	Front Hook