Fuel Pump: Installation

1. Apply a light coat of gasoline or spindle oil to a new O-ring, then install it into the fuel pump.
   Fig 1: Installing O-Ring

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2. Apply a light coat of gasoline or spindle oil to the O-ring of the fuel pump again, then push the fuel pump into the fuel filter.
   NOTE: Make sure that the O-ring is not cracked or jammed when installing.
   Fig 2: Pushing Fuel Pump Into Fuel Filter

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1. Apply a light coat of gasoline or spindle oil to 2 new O-rings, then install them onto the fuel pressure regulator.
   Fig 3: Installing O-Ring Onto Fuel Pressure Regulator

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2. Apply a light coat of gasoline or spindle oil to the O-rings of the fuel pressure regulator again, then push the fuel pressure regulator into the fuel filter.
   NOTE: Make sure that the O-ring is not cracked or jammed when installing.
   Fig 4: Pushing Fuel Pressure Regulator Into Fuel Filter

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1. Align the 5 claw positions, then install the fuel pump filter onto the fuel filter.
   Fig 5: Aligning Claw Positions For Installing Fuel Pump Filter

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1. Align the claw positions, then install the fuel suction support No. 1 onto fuel suction plate.
   Fig 6: Aligning Claw Positions For Installing Fuel Suction Support No. 1

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1. Connect the 2 fuel pump harness connectors.
   Fig 7: Connecting Fuel Pump Harness Connectors

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1. Align the 2 claw positions, then install the fuel suction plate and spring into the fuel suction case.
   Fig 8: Aligning Claw Positions For Installing Fuel Suction Plate And Spring

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2. Align the claw position, then install the fuel pump filter onto the fuel suction case.
   Fig 9: Aligning Claw Position For Installing Fuel Pump Filter Onto Fuel Suction Case

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3. Install a new E-ring.
   Fig 10: Installing E-Ring

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1. Slide the fuel sender gauge to fit the claw [A].
2. Connect the fuel sender gauge connector [B].
   Fig 11: Installing Fuel Sender Gauge Assembly

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1. Install a new gasket onto the fuel tank.
   Fig 12: Installing Gasket Onto Fuel Tank

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2. Set the fuel suction tube to the fuel tank.
   NOTE: Make sure that the fuel sender gauge arm does not bend.
3. Align the protrusion of the fuel suction tube with the notch of the fuel tank.
   Fig 13: Aligning Protrusion Of Fuel Suction Tube With Notch Of Fuel Tank

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4. While holding the fuel suction tube by hand, align the marks of a new fuel pump gauge retainer and fuel tank as shown, then install the fuel pump gauge retainer.
   Fig 14: Aligning Marks Of Fuel Pump Gauge Retainer And Fuel Tank

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5. Using SST and your hand, tighten it by 2 revolution so that the mark of the fuel pump gauge retainer comes within in the range shown in the illustration.

   SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

   NOTE: Use SST. Do not use any other tools such as a screwdriver.

   HINT:

   Insert the notch of SST into the rib of the fuel pump gauge retainer.

   Fig 15: Identifying Range For Mark Of Fuel Pump Gauge Retainer

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6. Connect the fuel tank vent hose.
   1. Align the fuel tank vent connector with the pipe, then push in the fuel tank vent connector until the retainer makes a "click" sound to connect the fuel tank vent hose to the fuel suction plate.
      NOTE:

      • Check that there are no scratches or foreign objects around the connected part of the fuel tank vent connector and pipe before performing this work.
      • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the quick connector.
        Fig 16: Connecting Fuel Tank Vent Hose

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7. Connect the fuel tank main tube.
   1. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
      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 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 cannot be pulled out.
        Fig 17: Connecting Fuel Tank Main Tube

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Torque: 5.4 Nm (55 kgf cm, 48 in. lbf) 

Check fuel leakage (See PRECAUTION  ).

1. Connect the fuel pump connector [A].
2. Install the rear floor service hole cover with the 4 screws [B].
   Fig 18: Installing Rear Floor Service Hole Cover

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1. Install the rear seat cushion with the 2 bolts.

   Torque: 41 Nm (420 kgf cm, 30 ft. lbf) 

   Fig 19: Installing Rear Seat Cushion With Bolts

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