FUEL PUMP INSTALLATION

PROCEDURE

  1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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

    2. Set the fuel suction tube with pump and gauge assembly to the fuel tank sub-assembly.

      Note:

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

    3. A390190C01

      *a

      Paint Mark

      Place a paint mark on the fuel suction tube with pump and gauge assembly as shown in the illustration.

      Tip:

      Perform this step only when replacing the fuel suction tube with pump and gauge assembly.

  2. INSTALL FUEL PUMP GAUGE RETAINER

    1. A390191C01

      *a

      Copy of Start of Threads Mark

      *b

      Start of Threads of the Fuel Pump Gauge Retainer

      *c

      Align
      V100135

      Press down
      V100136

      Front

      Align the start of the threads of a new fuel pump gauge retainer with the start of threads mark that was copied onto the vehicle body and while pushing down the fuel suction tube with pump and gauge assembly, attach the fuel pump gauge retainer.

    2. Install SST to the fuel pump gauge retainer.

      1. A390183C01

        *1

        Fuel Pump Gauge Retainer

        *a

        SST (Claw Set)

        *b

        Protrusion

        *c

        Notch

        *d

        Do not install SST (Claw Set)

        Set 4 SST (claw set) to the fuel pump gauge retainer.

        09808-14031

        09808-01080

        09808-01090

        09808-01100

        Note:

        • Align the notch of SST (claw set) with the protrusion of the fuel pump gauge retainer.

        • Do not install SST (claw set) to the start of threads location of the fuel pump gauge retainer.

      2. A390184C01

        *1

        Fuel Pump Gauge Retainer

        *a

        SST (Claw Set)

        *b

        Hook
        V100135

        Push
        V100136

        SST (Bolt)

        Push SST (claw set) against the fuel pump gauge retainer and tighten SST (bolt).

      3. A390185C01

        *a

        SST (Plate)

        *b

        SST (Claw Set)
        V100135

        SST (Bolt)

        Temporarily install SST (plate) to SST (claw set) with 4 SST (bolt).

        09808-14031

        09808-01030

        09808-01090

      4. A390186C01

        *a

        Center Point of Fuel Pump Gauge Retainer

        *b

        SST (Plate)
        V100135

        Front

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

      5. A390187C01

        *1

        Fuel Pump Gauge Retainer

        *a

        SST (Plate)

        *b

        SST (Claw Set)

        *c

        SST (Bolt)
        V100135

        Press

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

    3. A390192C01

      *1

      Fuel Pump Gauge Retainer

      *2

      Fuel Tank Assembly

      *a

      SST (Plate)

      *b

      Tighten approximately 90°

      *c

      Fuel pump gauge retainer rises up

      *d

      Cross Section

      *e

      Paint Mark
      V100135

      Press quickly and firmly
      V100136

      Front

      While pressing down on the fuel suction tube with pump and gauge assembly, have another person firmly press the fuel pump gauge retainer against the threads of the fuel tank assembly, and tighten the fuel pump gauge retainer by approximately 90°.

      Note:

      • To prevent damage to parts, do not turn SST too vigorously.

      • Do not turn the fuel pump gauge retainer if the paint marks become misaligned.

      • As the fuel pipes protrude above the fuel pump gauge retainer, SST should be removed and set as necessary to prevent it from contacting the pipes when installing the fuel pump gauge retainer.

    4. Quickly and firmly press down on the part of the fuel pump gauge retainer closest to the rear of the vehicle to keep it from rising up.

      Tip:

      • If the fuel pump gauge retainer cannot be properly pressed down due to the position of SST, set SST in a different position.

      • When fully pressing down the fuel pump gauge retainer, there will be a sound or tactile sensation of parts contacting each other, and at this point the fuel suction tube with pump and gauge assembly will stop rising up.

    5. A390193C01

      *a

      SST (Plate)

      *b

      One Person in Charge of Tightening

      *c

      One Person in Charge of Pressing Down

      *d

      Approximately 180°
      V100135

      Front

      While pressing down on the fuel suction tube with pump and gauge assembly, have another person slowly tighten the fuel pump gauge retainer by approximately 180°.

      Note:

      As the fuel pipes protrude above the fuel pump gauge retainer, SST should be removed and set as necessary to prevent it from contacting the pipes when installing the fuel pump gauge retainer.

    6. Check the tightening status of the fuel pump gauge retainer.

      1. A390194C01

        *1

        Fuel Pump Gauge Retainer

        *2

        Fuel Tank Assembly

        *a

        Measurement Position

        *b

        Vernier Caliper
        V100136

        Front

        Using a vernier caliper, measure the distance from the fuel tank assembly to the upper surface of the fuel pump gauge retainer at 3 positions as shown in the illustration.

        Standard

        Difference between the 3 measured values is 3 mm (0.118 in.) or less.

        Note:

        If the difference between measurements is approximately 6 mm (0.236 in.), the threads are cross-threaded by 1 row (6 mm (0.236 in.)), so remove and reinstall the fuel pump gauge retainer.

    7. A390195C01

      *a

      SST (Handle)

      *b

      SST (Plate)

      *c

      One Person in Charge of Tightening

      *d

      One Person in Charge of Pressing Down

      *e

      Approximately 90°
      V100135

      Front

      Install SST (handle) to SST (plate).

      09808-14031

      09808-01010

      09808-01020

    8. While pressing down on the fuel suction tube with pump and gauge assembly, have another person use SST (handle) to slowly tighten the fuel pump gauge retainer approximately 90°.

      Note:

      As the fuel pipes protrude above the fuel pump gauge retainer, SST should be removed and set as necessary to prevent it from contacting the pipes when installing the fuel pump gauge retainer.

    9. A390196C01

      *a

      SST (Handle)

      *b

      SST (Plate)

      *c

      Copy of Fully Tightened Mark

      *d

      Start of Threads of the Fuel Pump Gauge Retainer
      V100135

      Tighten
      V100136

      Front

      Slowly tighten the fuel pump gauge retainer until it reaches the fully tightened mark that was copied onto the vehicle body.

      Note:

      As the fuel pipes protrude above the fuel pump gauge retainer, SST should be removed and set as necessary to prevent it from contacting the pipes when installing the fuel pump gauge retainer.

  3. CHECK AIRTIGHTNESS

    1. A390197C01

      *a

      Soapy Water Application Area

      Apply soapy water to the contact areas between the fuel suction tube with pump and gauge assembly and the fuel pump gauge retainer.

      Note:

      Cover the connector of the fuel suction tube with pump and gauge assembly with protective tape.

    2. A322318C01

      *a

      Vacuum Pump

      *b

      Port (A)

      Install a vacuum pump to the port (A) of the fuel suction tube with pump and gauge assembly as shown in the illustration.

    3. A323532C01

      *a

      Port (A)

      *b

      Port (B)

      *c

      Vacuum Pump

      Close the port (B) and use the vacuum pump to apply 5 kPa (0.1 kgf/cm2, 0.7 psi) of compressed air to the port (A) as shown in the illustration.

      Note:

      Do not apply more compressed air than necessary.

    4. Check that the contact areas between the fuel suction tube with pump and gauge assembly and fuel pump gauge retainer are airtight.

      Note:

      • If air bubbles appear, remove and reinstall the fuel pump gauge retainer.

      • After a fuel pump gauge retainer and fuel suction tube set gasket have been used once, replace them with new parts.

      • When removing and reinstalling the fuel pump gauge retainer, make sure to clean away the soapy water to prevent the fuel suction tube set gasket from slipping out of position and being assembled incorrectly.

      A390198C01

      *a

      Air Bubbles
      Tip:

      If the assembled components are not airtight due to improper installation of the fuel pump gauge retainer, etc., air bubbles will appear as shown in the illustration.

  4. CONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY

    Note:

    Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

    1. A322307C01

      *a

      Fuel Tube Connector

      *b

      Fuel Pipe

      *c

      Retainer

      *d

      O-ring
      V100135

      Push

      Connect the No. 1 fuel emission tube sub-assembly to the fuel suction tube with pump and gauge assembly.

      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

  5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    Note:

    Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

    1. A322305C01

      *a

      Retainer

      *b

      O-ring

      *c

      Fuel Tube Connector

      *d

      Nylon Tube

      *e

      Fuel Pipe
      V100135

      Push

      Connect the fuel tank main tube sub-assembly to the fuel suction tube with pump and gauge assembly.

      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

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  7. INSPECT FOR FUEL LEAK

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  8. INSTALL REAR FLOOR SERVICE HOLE COVER

    1. Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.

    2. Clean the installation surfaces of the rear floor service hole cover and vehicle body.

    3. Connect the fuel pump connector.

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

    5. Connect the rear seat inner with center belt assembly LH connector and rear seat inner with center belt assembly RH connector.

  9. INSTALL REAR SEAT ASSEMBLY (for Separate Seat Type)

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  10. INSTALL REAR SEAT ASSEMBLY (for Bench Seat Type)

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