FUEL PUMP INSTALLATION


  1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE


    1. A01JBXS

      Install a new gasket onto the fuel tank.

    2. A01J982E01

      Set the fuel suction tube assembly with pump and gauge 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 notchs of the fuel tank.

  2. INSTALL FUEL PUMP GAUGE RETAINER


    1. A01JC1IE01
      Text in Illustration
      *1 Start Mark
      *2 Mark
      *3 Front Side

      While holding the fuel suction tube assembly with pump and gauge 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.

    2. A01JANJE03
      Text in Illustration
      *1 Claw
      *2 Rib

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

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

      Tech Tips


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

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

    3. A01JCENE01
      Text in Illustration
      *1 Hold
      *2 Turn
      *3 Mark
      *4 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
      09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

      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.

      • Tighten the retainer by turning it clockwise while holding SST down.

      Tech Tips

      The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

  3. CONNECT FUEL TANK EVAPORATION TUBE


    1. A01JAHJE01
      Text in Illustration
      *1 Retainer

      Connect the fuel tank evaporation tube to the fuel suction tube assembly.

  4. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A01JCCK

      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.

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


    1. A01JC5KE01

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

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01JBD7E01
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tube Joint
      *3 O-ring
      *4 Collars

      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 objects 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.

    2. A01JARN

      Connect the fuel pump connector.

  7. CONNECT CABLE TO NEGATIVE 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


    1. Check fuel pump operation.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the power switch on (IG).

        Note

        Do not start the engine.

      3. Turn the intelligent tester 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 intelligent tester from the DLC3.

  9. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. A01JC7A

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

  10. INSTALL REAR SEAT CUSHION ASSEMBLY


    1. A01JCUFE01
      Text in Illustration
      *1 100 mm (3.94 in.) or less
      *2 Guide
      *3 Hook

      Engage the 2 guides of the seat cushion to the seatback.

    2. Engage the 2 front hooks of the seat cushion to the vehicle body.

      Note

      When installing the seat cushion, make sure that the seat belt buckle is not under the seat cushion.

      Tech Tips

      Confirm that the seat cushion is firmly installed.

  11. INSTALL REAR NO. 3 FLOOR BOARD


    1. A01JC33

      Engage the 2 guides to install the rear No. 3 floor board.

  12. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  13. INSTALL REAR NO. 2 FLOOR BOARD


    1. A01JCWRE01

      Engage the 3 guides <A>.

    2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.