FUEL PUMP INSTALLATION

CAUTION / NOTICE / HINT

Tip:

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

PROCEDURE

  1. INSPECT FITTING OF FUEL PUMP GAUGE RETAINER

    1. Inspect the fuel pump gauge retainer.

      1. Install the fuel pump gauge retainer to the fuel tank by hand with the fuel suction with pump disconnected.

        • If the fuel pump gauge retainer can be turned 180° or more by hand, reuse the retainer.

        • If the fuel pump gauge retainer cannot be turned 180° or more by hand, replace it with a new one.

        Tip:

        Check that there is no damage, dents, foreign matter, or other defects on the threads of the fuel tank.

  2. INSTALL FUEL SUCTION WITH PUMP ASSEMBLY

    1. A204401E04

      Install a new gasket onto the fuel tank.

      Table 1. Text in Illustration

      *1

      New Gasket
    2. A217083E04

      Set the fuel suction with pump to the fuel tank.

      Note:

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

    3. Align the protrusion of the fuel suction with pump with the notch of the fuel tank.

      Table 2. Text in Illustration

      *1

      Notch

      *2

      Protrusion
    4. A217066E04

      While holding the fuel suction with pump and gauge tube by hand to prevent it from tilting, align the start marks on a new fuel pump gauge retainer and fuel tank and tighten the fuel pump gauge retainer 180° by hand.

      Table 3. Text in Illustration

      *1

      Start Mark

      (Fuel Tank Side)

      *2

      Start Mark

      (Fuel Pump Gauge Retainer Side)
      V100135

      Front Side of Vehicle
      Tip:

      Check that there is no damage, dents, foreign matter, or other defects on the threads of the fuel tank.

    5. A246336E04

      Temporarily install SST (plate and 2 claws) to the fuel pump gauge retainer.

      09808-14030

      Table 4. Text in Illustration

      *1

      SST (Plate)

      *2

      SST (Claw)
      Tip:

      • Be sure to use 2 SST (claws) as shown in the illustration.

      • Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.

    6. While securely pressing SST (claws) against the fuel pump gauge retainer ribs, install the 2 bolts.

      Tip:

      Install SST while pressing SST (claws) against the fuel pump gauge retainer (towards the center of SST).

    7. Install SST (handle).

    8. A246338E04

      Tighten the fuel pump gauge retainer approximately 270° so that the start mark on the fuel pump gauge retainer is in the position shown in the illustration.

      09808-14030

      Table 5. Text in Illustration

      *1

      Start Mark

      (Fuel Pump Gauge Retainer Side)
      V100135

      Turn
      V100136

      Front Side of Vehicle
      Note:

      • Do not use any tools other than those specified in this operation. Damage to the fuel pump gauge retainer or fuel tank may result.

      • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.

      • Make sure to rotate SST (handle) horizontally. If SST (handle) is rotated at an angle, SST may come off.

      • Do not spin SST too fast or use an impact wrench as this may result in damage to components.

      • If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.

      Tip:

      • Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing SST, rotate the handle slowly to tighten the fuel pump gauge retainer.

      • The tips of SST (claws) can be fitted onto the ribs of the fuel pump gauge retainer.

  3. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE

    1. A217275E02

      Connect the No. 1 charcoal canister outlet hose to the fuel suction with pump.

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

    1. A217274E01

      Connect the No. 1 fuel evaporation tube to the fuel suction with pump with the clip.

  5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

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

      A390595E01
      Table 6. Text in Illustration

      *1

      Fuel Tube Joint

      *2

      Tube Joint Clip

      *3

      O-Ring
      Note:

      • Check that there are no scratches or foreign objects around the connected part of the fuel tube joint and plug before performing this work.

      • Check that the fuel tube joint is securely and fully inserted.

      • 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 cannot be pulled out.

    2. A213637

      Connect the fuel pump connector.

  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

  7. INSPECT FOR FUEL LEAK

    Click here

  8. INSTALL REAR FLOOR SERVICE HOLE COVER

    1. A213638

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

  9. INSTALL REAR CENTER SEAT ASSEMBLY (w/ REAR NO. 1 SEAT)

    1. Install the center seat (Click here).

  10. INSTALL REAR NO. 1 SEAT ASSEMBLY (w/ REAR NO. 1 SEAT)

    1. Install the rear No. 1 seat (Click here).