FUEL PUMP INSTALLATION


  1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE


    1. A003SETE05
      Text in Illustration
      *1 Gasket

      Install a new gasket onto the fuel tank.

    2. A003T3EE04
      Text in Illustration
      *1 Notch
      *2 Protrusion

      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 notches of the fuel tank.

  2. INSTALL FUEL PUMP GAUGE RETAINER


    1. A003SORE02
      Text in Illustration
      *1 Start Mark
      *2 Mark
      *a Front Side

      While holding the fuel suction tube assembly with pump and gauge by hand to prevent it from tilting, align the mark on a 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. A003UUUE01
      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. A003U2EE01
      Text in Illustration
      *1 Mark
      *a Hold
      *b Turn
      *c 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. A003RZHE01
      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. Connect the No. 1 charcoal canister outlet hose to the fuel suction tube assembly.

      Tech Tips

      After connecting the fuel tank evaporation tube and No. 1 charcoal canister outlet hose, check that the fuel tank evaporation tube is positioned below the No. 1 charcoal canister outlet hose.

  5. 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.

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A003U45E02
      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 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. A003RGK

      Connect the fuel pump connector.

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  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. A003TUD

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

    2. Install the rear floor carpet, and engage the floor carpet hook.

  10. INSTALL REAR DOOR SCUFF PLATE LH


    1. Engage the 8 claws and install the rear door scuff plate LH.

  11. INSTALL REAR SEAT ASSEMBLY LH

    Click here

  12. INSTALL BATTERY BOX COVER


    1. Engage the 3 guides to install the battery box cover.

  13. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  14. INSTALL REAR FLOOR MAT


    1. Install the rear floor mat.