FUEL PUMP INSTALLATION

INSTALL FUEL SENDER GAUGE ASSEMBLY
1. Install the fuel sender gauge assembly by sliding it downward.
2. Attach the wire harness clamp.
3. Connect the fuel sender gauge assembly connector.
INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
1. Text in Illustration
  
  *1 Gasket
  
  Apply a light coat of fuel to a new gasket and install the gasket to the fuel tank assembly.
2. Install the fuel suction with pump and gauge tube assembly to the fuel tank assembly.
  
  Note
  
  Make sure that the fuel sender gauge assembly arm does not bend.
3. Text in Illustration
  
  *a Notch
  
  *b Protrusion
  
  Align the protrusions of the fuel suction with pump and gauge tube assembly with the notches of the fuel tank assembly.

Text in Illustration
*1	Gasket

Text in Illustration
*a	Notch
*b	Protrusion

INSTALL FUEL PUMP GAUGE RETAINER

Text in Illustration
*1	Fuel Pump Gauge Retainer
*a	CORRECT
*b	INCORRECT
*c	SST (Claw)

Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

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

Note

Install SST (claw) to the correct location.

Text in Illustration

*a Center Point of Fuel Pump Gauge Retainer

Adjust the position of SST (claw) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.

Text in Illustration
*a	Center Point of Fuel Pump Gauge Retainer

Text in Illustration
*a	SST (Plate)
*b	SST (Claw)
*c	SST (Bolt)
	Press

Press SST (claw) against the rib of the fuel pump gauge retainer and tighten SST (bolt).

Text in Illustration
*a	Start Mark (Fuel Tank Assembly)
*b	Start Mark (Fuel Pump Gauge Retainer)
	Front of Vehicle

Align the start marks on the fuel pump gauge retainer and fuel tank assembly as shown in the illustration.

Note

Replace the fuel pump gauge retainer with a new one if not installed properly.

Text in Illustration
*a	SST (Plate)
*b	Start Mark (Fuel Pump Gauge Retainer)
*c	Worker A
*d	Worker B
*e	Approximately 180°
	Press Down
	Slowly Rotate
	Front of Vehicle

While one person presses down to prevent the fuel pump gauge retainer and the fuel suction with pump and gauge tube assembly from rotating together, the other person should firmly press the fuel pump gauge retainer against the threads of the fuel tank assembly, and tighten it by rotating it approximately 180°.

CAUTION:

Make sure not to pinch your hands with SST.

Note

Be careful not to apply excessive downward force to SST, as this may damage the fuel suction with pump and gauge tube assembly or fuel tank assembly.
Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so make sure SST is horizontal when turning it.
To prevent damage to parts, do not turn SST too vigorously.
If SST slips off of the fuel pump gauge retainer, loosen SST (bolt) and install SST again.

As shown in the illustration, quickly and firmly press down on the part of the fuel pump gauge retainer closest to the front side of the vehicle so that it no longer rises up.

Text in Illustration
*1	Fuel Pump Gauge Retainer	*2	Fuel Tank Assembly
*a	SST (Plate)	*b	Press Quickly and Firmly
*c	Fuel Pump Gauge Retainer Rise Up Area	*d	Front of Vehicle

Tech Tips

If the fuel pump gauge retainer cannot be properly pressed down due to the position of SST, set SST in a different position.
When pressing down the fuel pump gauge retainer, there will be a sound or feeling of parts contacting and pressing together when the fuel pump gauge retainer is fully pressed down, and at this point it will stop rising up.

Text in Illustration
*a	SST (Plate)
*b	Start Mark (Fuel Pump Gauge Retainer)
*c	Start Mark (Fuel Tank Assembly)
*d	Worker A
*e	Worker B
*f	Rotate to Start Mark on Fuel Tank Assembly
	Press Down
	Slowly Rotate
	Front Side of Vehicle

While one person presses down to prevent the fuel pump gauge retainer and the fuel suction with pump and gauge tube assembly from rotating together, the other person should slowly rotate SST (plate) and tighten the fuel pump gauge retainer until it reaches the start mark on the fuel tank assembly.

CAUTION:

Make sure not to pinch your hands with SST.

Check the tightening condition of the fuel pump gauge retainer.

Text in Illustration
*1	Fuel Pump Gauge Retainer
*2	Fuel Tank Assembly
*a	Measurement Location
*b	Vernier Caliper
	Front of Vehicle

Using a vernier caliper, measure the upper surface of the fuel tank assembly in the 3 locations shown in the illustration.

Specification
Difference between the 3 measured values is within 3.0 mm (0.118 in.).

Note

If the difference between measurements is approximately 6.0 mm (0.236 in.), the threads are cross-threaded by one row (6.0 mm (0.236 in.)), so remove and reinstall the fuel pump gauge retainer.

Install SST (handle) to SST (plate).

SST

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

Text in Illustration
*a	SST (Handle)
*b	SST (Plate)
*c	Start Mark (Fuel Pump Gauge Retainer)
*d	Worker A
*e	Worker B
*f	Approximately 70°
	Press Down
	Slowly Rotate
	Front Side of Vehicle

While one person presses down to prevent the fuel pump gauge retainer and the fuel suction with pump and gauge tube assembly from rotating together, the other person should slowly rotate SST (handle) and tighten the fuel pump gauge retainer by approximately 70°.

CAUTION:

Make sure not to pinch your hands with SST.

Text in Illustration
*a	SST (Handle)
*b	SST (Plate)
*c	Start Mark (Fuel Pump Gauge Retainer)
*d	Worker A
*e	Worker B
*f	Fully Tightened Position
	Hold Down
	Slowly Rotate
	Front Side of Vehicle

To make sure SST does not separate from the fuel pump gauge retainer, one person should hold down the center of SST from above while at the same time both people slowly rotate SST (handle) and slowly tighten the fuel pump gauge retainer until it reaches the fully tightened position.

INSTALL TANK SUCTION TUBE SUPPORT
1. Attach the 2 claws to install the tank suction tube support.

CONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY (w/ Combustion Type Power Heater)

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 into the plug of the fuel suction with pump and gauge tube assembly, and then install the tube joint clip.

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 clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.

CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

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 into the plug of the fuel suction with pump and gauge tube assembly, and then install the tube joint clip.

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 clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.

CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY

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 into the plug of the fuel suction with pump and gauge tube assembly, and then install the tube joint clip.

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 clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.

CHECK AIRTIGHTNESS
1. After installing the fuel suction tube, check for fuel leaks by first applying soapy water to the area where the suction plate and retainer contact, and then blow your breath forcefully through a flexible pouring spout or similar tube into the fuel inlet area.
  1. Blow forcefully until the reverse flow prevention valve inside the fuel inlet activates.
    
    Note
    
    Be careful not to inhale any fuel vapor.
    
    Tech Tips
    
    There should be a faintly audible sound when the reverse flow prevention valve operates.
2. If improper installation of the fuel suction with pump and gauge tube assembly, etc. has resulted in a condition where fuel will leak, air will leak out as shown in the illustration.
  
  Note
  
  If air leaks out, recheck the installation condition, and replace the used fuel pump gauge retainer and gasket with new ones. Also, make sure to fully clean away the soapy water. (Any remaining soapy water can cause the gasket to slip and result in an improper assembly.)
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Connect the fuel suction with pump and gauge tube assembly connector.
2. Install the rear floor service hole cover with new butyl tape.
  
  Note
  
  Be careful that the rear floor service hole cover does not overlap the protrusions of the floor panel when installing.
INSPECT FOR FUEL LEAK
1. Check fuel pump operation.
  1. Connect the GTS to the DLC3.
  2. Turn the ignition switch to ON and turn the GTS on.
    
    Note
    
    Do not start the engine.
  3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Actuator Test of FPC (EU5).
  4. 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 No. 1 integration relay, fuel suction with pump and gauge tube assembly, ECM and wiring connectors.
2. Inspect for fuel leaks.
  1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.
3. Turn the ignition switch off.
4. Disconnect the GTS from the DLC3.
INSTALL REAR CENTER SEAT ASSEMBLY (w/ Rear No. 1 Seat)

Click here
INSTALL REAR NO. 1 SEAT ASSEMBLY (w/ Rear No. 1 Seat)

Click here