FUEL PUMP INSTALLATION

Tech Tips

Perform "Inspection After Repairs" after replacing the fuel pump Click here.


  1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

    Tech Tips

    Perform "Inspection After Repairs" after replacing the fuel pump Click here.


    1. Install a new fuel suction tube set gasket to the fuel tank assembly.

    2. Connect the fuel return vent tube sub-assembly and set the fuel suction tube assembly with pump and gauge into the fuel tank assembly.

      Note


      • Be careful not to bend the arm of the fuel sender gauge.

      • When connecting the fuel tube connector, do not forcibly pull the fuel return vent tube sub-assembly.

    3. A01FTIME01
      Text in Illustration
      *1 Protrusion
      A01FTNO Hole

      Align the protrusions of the fuel suction tube assembly with pump and gauge with the holes in the fuel tank assembly.

    4. While pressing down on the fuel suction tube assembly with pump and gauge, temporarily install the fuel pump gauge retainer.

    5. A01FTIWE01
      Text in Illustration
      *1 Insertion Point

      Set the 2 claws and plate of SST on the fuel pump gauge retainer.

      SST
      09808-14030   ( 09808-01010, 09808-01030, 09808-01040 )

      Tech Tips

      Securely insert the ends of SST into the insertion points in the fuel pump gauge retainer.

    6. While firmly pressing the claws of SST into the insertion points in the fuel pump gauge retainer, tighten the bolts of the claws.

    7. Attach the handle of SST.

    8. A01FSIRE01
      Text in Illustration
      *1 Protrusion
      *2 Groove
      A01FRJI Front of Vehicle

      Using SST, rotate the fuel pump gauge retainer so that the protrusions of the retainer are aligned with the grooves in the fuel tank assembly to install the fuel suction tube assembly with pump and gauge to the fuel tank assembly.

      Note


      • Do not use any tools other than SST, such as a screwdriver, etc.

      • Do not use excessive force when pressing down on SST, as the fuel pump gauge retainer will place excessive force on the fuel suction tube assembly with pump and gauge and be difficult to remove, and parts may be damaged.

      • Be sure to keep the handle level when turning it, as SST may slip off the retainer if the handle is turned at an angle with excessive force.

      • Do not use an impact wrench or turn the handle with excessive force, as parts may be damaged.

      • If SST slips off the retainer, loosen the bolts and reattach SST to the retainer.

      • Make sure that the fuel suction tube set gasket does not come off.

    9. Install the No. 1 fuel tube clamp.

    10. A01FRKHE01
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Suction Plate Sub-assembly
      *5 Collar
      *a CORRECT
      *b INCORRECT

      Insert the fuel tank main tube sub-assembly and fuel tank return tube into the plugs of the fuel suction plate sub-assembly and fix them in place with the 2 tube joint clips.

      Note


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

      • Check that the fuel tube joint is inserted securely.

      • Check that the tube joint clips are on the collars of the fuel tube joints.

      • After installing the tube joint clips, check that the fuel tube joints have not been pulled off.

      • Be careful not to damage any clips. If a clip is damaged, replace it.

    11. Connect the fuel suction tube connector.

  2. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. INSPECT FOR FUEL LEAK


    1. Connect the GTS to the DLC3.


      1. Turn the power switch on (IG).

        Note

        Do not start the engine.

      2. Turn the GTS on.

      3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

    2. Check the fuel pump operation.


      1. Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard.

        If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.

    3. Inspect for fuel leaks.


      1. Check that there are no fuel leaks anywhere in the system after performing maintenance.

        If there is a fuel leak, repair or replace parts as necessary.

  4. INSTALL REAR FLOOR SERVICE HOLE COVER


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

  5. INSTALL NO. 3 ROOM PARTITION PAD


    1. Install the No. 3 room partition pad with the clip.

  6. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY

    Click here