FUEL PUMP INSTALLATION

PROCEDURE

1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

   1. 

      *1	Fuel Suction Tube Set Gasket

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

   2. 

      *a	Notch
      *b	Protrusion

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

      Note:

      Make sure that the fuel sender gauge arm does not bend.

   3. Align the protrusions of the fuel suction tube with pump and gauge assembly with the notches of the fuel tank assembly.

2. INSTALL FUEL PUMP GAUGE RETAINER

   1. Install SST to the fuel pump gauge retainer.

      1. 

         *1	Fuel Pump Gauge Retainer
         *a	SST (Claw)
         *b	Correct
         *c	Incorrect

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

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         Note:

         Install SST (claw) to the correct location.

      2. 

         *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.

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

   2. 

      *a	Front
      *b	Press
      *c	Start of Threads of the Fuel Pump Gauge Retainer
      *d	Copy of Start of Threads Mark
      *e	Align

      While pressing down on the fuel pump, have another person align the start of the threads of the fuel pump gauge retainer with the start of the threads mark that was copied onto the vehicle body.

   3. 

      *1	Fuel Pump Gauge Retainer
      *2	Fuel Tank Assembly
      *a	Front
      *b	Tighten approximately 90°
      *c	Fuel Pump Gauge Retainer rises up
      *d	Press quickly and firmly
      *e	Cross Section

      While pressing down on the fuel pump, 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°.

   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.

      Note:

      • Be careful not to apply excessive downward force to SST, as this may damage the fuel pump or fuel tank assembly.

      • Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so be sure SST is horizontal when turning.

      • 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.

      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 pressing down the fuel pump gauge retainer, there will be a sound or tactile sensation of parts contacting and pressing together when the fuel pump gauge retainer is fully pressed down, and at this point the fuel pump will stop rising up.

   5. 

      *a	One Person in Charge of Tightening
      *b	One Person in Charge of Holding
      *c	Front
      *d	Tighten approximately 180°

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

   6. 

      *a	Front
      *b	Measurement Position
      *c	Vernier Caliper
      *d	A-A Cross Section

      Check the tightening status of the pump gauge retainer.

      1. 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. Install SST (handle).

   8. 

      *a	One Person in Charge of Tightening
      *b	One Person in Charge of Holding
      *c	Start of Threads of the Fuel Pump Gauge Retainer
      *d	Copy of Fully Tightened Mark
      *e	Front

      While pressing down on the fuel pump, have another person use the SST (handle) to slowly tighten the fuel pump gauge retainer by 90°(after tightening, there will be remaining until the fully tightened mark).

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   9. 

      *a	Hold Down
      *b	Pull

      While holding down on the center of SST (handle) to prevent SST from separating from the fuel pump gauge retainer, pull SST (handle) with another person pulling the opposite end of SST (handle), and slowly tighten the fuel pump gauge retainer until it reaches the fully tightened mark.

3. CONNECT NO. 2 FUEL TANK EVAPORATION TUBE

   1. 

      *a

      Retainer

      Connect the No. 2 fuel tank evaporation tube to the fuel suction tube with pump and gauge assembly.

4. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE

   1. Connect the No. 1 charcoal canister outlet hose to the fuel suction tube with pump and gauge assembly.

      Tip:

      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. Connect the No. 1 fuel evaporation tube sub-assembly to the fuel suction tube with pump and gauge assembly and slide the clip secure it.

6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

   1. Push the fuel tube joint onto the plug of the fuel suction plate sub-assembly, then install the tube joint clip.

      

      *1	Tube Joint Clip	-	-
      *a	Fuel Tube Joint	*b	O-ring
      *c	Collar	*d	Correct
      *e	Incorrect	-	-

      Note:

      • Check that there are no scratches or foreign matter around the connecting parts 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 sub-assembly cannot be pushed out.

7. CHECK AIRTIGHTNESS

   1. 

      *a	Vacuum Pump
      *b	Port A

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

   2. 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 connectors of the fuel suction tube with pump and gauge assembly with protective tape.

   3. 

      *a	Port A
      *b	Port B
      *c	Port C
      *d	Vacuum Pump

      Close port (B), port (C) and use the vacuum pump to apply 5 kPa (0.1 kgf/cm², 1 psi) of compressed air to 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.

      

      *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.

8. 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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9. INSPECT FOR FUEL LEAK

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10. INSTALL REAR FLOOR SERVICE HOLE COVER

    1. 

       Connect the fuel pump connector.

    2. 

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

    3. Connect the 2 connectors.

11. INSTALL REAR SEAT CUSHION ASSEMBLY

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