FUEL PUMP INSTALLATION


  1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE


    1. A003WE8E05
      Text in Illustration
      *1 Gasket

      Install a new gasket onto the fuel tank.

    2. A003X2YE04
      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. A003V9QE01
      Text in Illustration
      *1 Start Mark
      *2 Mark
      *3 Front

      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, dents, foreign matter or other defects on the threads of the fuel tank.

    2. A003W9BE01
      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.

    3. 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).

    4. Install the SST handle.

    5. A003X4AE01
      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.

  3. CONNECT FUEL TANK EVAPORATION TUBE


    1. A003YI0E01
      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. A003VS3

      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. A003YGZE01

      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. A003WWGE02
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tube Joint
      *3 O-ring
      *4 Collar
      *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.

    2. A003Y96

      Connect the fuel pump connector.

  7. 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.

  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 are no fuel leaks after performing maintenance anywhere on the fuel system. If there are fuel leaks, 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. A003VCS

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

  10. INSTALL REAR SEAT CUSHION LOCK HOOK


    1. A003YR7

      Engage the claw to install a new rear seat cushion lock hook.

      Note

      Rear seat cushion lock hooks must not be reused.

      Tech Tips

      Use the same procedure the LH side and RH side.

  11. 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. A003XOT

      Pass the rear center seat outer belt assembly through the rear seat cushion assembly.

    3. Install the rear center seat outer belt assembly with the bolt.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }
    4. A003W09

      Engage the guide as shown in the illustration.

    5. Pass the rear seat inner with center belt assembly LH and rear seat inner belt assembly through the rear seat cushion assembly as shown in the illustration.

      A003Z3XE01
      Text in Illustration
      *1 Rear Seat Inner Belt Assembly *2 Rear Seat Inner with Center Belt Assembly LH
    6. A003YOA

      Engage the 2 hooks of the seat cushion to the vehicle body as shown in the illustration.

    7. Confirm that the seat cushion is firmly installed.

      Note

      When installing the seat cushion, make sure that the seat belt buckles are not under the seat cushion.

  12. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE


    1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.

  13. INSTALL DECK FLOOR BOX RH


    1. Engage the 6 guides.

    2. Install the deck floor box RH with the clip.

  14. INSTALL REAR NO. 3 FLOOR BOARD


    1. Install the rear No. 3 floor board.

  15. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  16. INSTALL REAR NO. 2 FLOOR BOARD


    1. Install the rear No. 2 floor board.