FUEL PUMP INSTALLATION

INSTALL FUEL SENDER GAUGE ASSEMBLY

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INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

*1	Fuel Suction Tube Set Gasket

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

*a	Notch
*b	Protrusion

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

Note:

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

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

*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.

INSTALL FUEL PUMP GAUGE RETAINER

*a	Copy of Start of Threads Mark
*b	Start of Threads of the Fuel Pump Gauge Retainer
*c	Align
	Press down
	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.

Install SST to the fuel pump gauge retainer.

*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.

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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.

*1	Fuel Pump Gauge Retainer
*a	SST (Claw Set)
*b	Hook
	Push
	SST (Bolt)

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

*a	SST (Plate)
*b	SST (Claw Set)
	SST (Bolt)

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

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*a	Center Point of Fuel Pump Gauge Retainer
*b	SST (Plate)
	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.

*1	Fuel Pump Gauge Retainer
*a	SST (Plate)
*b	SST (Claw Set)
*c	SST (Bolt)
	Press

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

*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
	Press quickly and firmly
	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.

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.

*a	SST (Plate)
*b	One Person in Charge of Tightening
*c	One Person in Charge of Pressing Down
*d	Approximately 180°
	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°.

Check the tightening status of the fuel pump gauge retainer.

*1	Fuel Pump Gauge Retainer
*2	Fuel Tank Assembly
*a	Measurement Position
*b	Vernier Caliper
	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.

*a	SST (Handle)
*b	SST (Plate)
*c	One Person in Charge of Tightening
*d	One Person in Charge of Pressing Down
*e	Approximately 90°
	Front

Install SST (handle) to SST (plate).

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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°.

*a	SST (Handle)
*b	SST (Plate)
*c	Copy of Fully Tightened Mark
*d	Start of Threads of the Fuel Pump Gauge Retainer
	Tighten
	Front

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

INSTALL TANK SUCTION TUBE SUPPORT

Engage the 2 claws to install the tank suction tube support.

	Push

Install the fuel tank evaporation vent tube sub-assembly.

Note:

Securely install the fuel tank evaporation vent tube sub-assembly by pushing it until it makes a "click" sound.

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

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

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

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 as shown in the illustration.
After installing the tube joint clip, check that the No. 2 fuel main tube sub-assembly is securely connected by pulling on it.

CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

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

*A	w/o Combustion Type Power Heater	*B	w/ Combustion Type Power Heater
*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 as shown in the illustration.
After installing the tube joint clip, check that the fuel tank main tube sub-assembly is securely connected by pulling on it.

CONNECT FUEL RETURN TUBE SUB-ASSEMBLY

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

*A	w/o Combustion Type Power Heater	*B	w/ Combustion Type Power Heater
*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 as shown in the illustration.
After installing the tube joint clip, check that the fuel return tube sub-assembly is securely connected by pulling on it.

CHECK AIRTIGHTNESS

*A	w/o Combustion Type Power Heater
*B	w/ Combustion Type Power Heater
*a	Soapy Water Application Area

After installing the fuel suction tube with pump and gauge assembly, check for fuel leaks by first applying soapy water to the area where the fuel suction plate sub-assembly and fuel pump gauge retainer contact, and then blow forcefully into the fuel inlet area through a flexible pouring spout or similar tube.

*a	Air

Blow forcefully until the reverse flow prevention valve inside the fuel inlet activates.

CAUTION:

Be careful not to inhale any fuel vapor.

Tip:

There should be a faintly audible sound when the reverse flow prevention valve operates.

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	w/o Combustion Type Power Heater
*B	w/ Combustion Type Power Heater
*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.

INSPECT FOR FUEL LEAK

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INSTALL REAR FLOOR SERVICE HOLE COVER

Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.
Clean the installation surfaces of the rear floor service hole cover and vehicle body.
Connect the fuel pump connector.
Install the rear floor service hole cover with new butyl tape.
Connect the 2 connectors.

INSTALL REAR SEAT CUSHION ASSEMBLY

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