Tech Tips
Perform "Inspection After Repairs" after replacing the fuel pump.
w/ EGR System Click here
w/o EGR System Click here
INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
Tech Tips
Perform "Inspection After Repairs" after replacing the fuel pump.
w/ EGR System Click here
w/o EGR System Click here
Install a new fuel suction tube set gasket to the fuel tank assembly.
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.
*a | Protrusion |
Hole |
Align the protrusions of the fuel suction tube assembly with pump and gauge with the holes in the fuel tank assembly.
While pressing down on the fuel suction tube assembly with pump and gauge, temporarily install the fuel pump gauge retainer.
*a | Insertion Point |
Set the 2 claws and plate of SST on the fuel pump gauge retainer.
Tech Tips
Securely insert the ends of SST into the insertion points in the fuel pump gauge retainer.
While firmly pressing the claws of SST into the insertion points in the fuel pump gauge retainer, tighten the bolts of the claws.
Attach the handle of SST.
*a | Protrusion |
*b | Groove |
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.
Install the No. 1 fuel tube clamp.
*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 into the plugs of the fuel suction plate sub-assembly and fix them in place with 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 has not been pulled off.
Be careful not to damage any tube joint clip. If a tube joint clip is damaged, replace it.
Connect the fuel pump connector.
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.
INSPECT FOR FUEL LEAK
Check fuel pump with filter assembly operation.
Connect the GTS to the DLC3.
Turn the power switch on (IG).
Note
Do not start the engine.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
Check for pressure in the fuel tube sub-assembly from the fuel line. Check that sounds of fuel flowing from the fuel tank assembly can be heard.
If no sounds can be heard, check the No. 1 integration relay, fuel pump with filter assembly, ECM and wiring connectors.
Inspect for fuel leaks.
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.
Turn the power switch off.
Disconnect the GTS from the DLC3.
INSTALL REAR FLOOR SERVICE HOLE COVER
Install the rear floor service hole cover with new butyl tape.
INSTALL NO. 3 ROOM PARTITION PAD
Install the No. 3 room partition pad with the clip.
INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY