Installation (from 07/2011)
1NZ-FE FUEL: FUEL PUMP (for Hatchback): INSTALLATION
HINT
If the fuel pump has been replaced, conduct Inspection After Repairs Programming and Relearning.
1. INSTALL FUEL SUCTION TUBE SET GASKET
(a) Coat a new fuel suction tube gasket with gasoline and install it to the fuel tank.
2. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
HINT
If the fuel pump has been replaced, conduct Inspection After Repairs Programming and Relearning.
(a) Pass the float of the fuel sender gauge assembly into the fuel tank.
(b) Bend up the tip of the fuel pump filter and set the fuel suction tube assembly on the fuel tank.
NOTICE:
Be careful not to bend the arm of the fuel sender gauge assembly.
3. INSTALL FUEL PUMP GAUGE RETAINER
(a) Align the tab of the fuel suction tube assembly with the groove of the fuel tank.
(b) Align the retainer mark (start of threads) with the start of the threads on the fuel tank, and while pressing down on the fuel suction tube assembly, install a new fuel pump gauge retainer and tighten it by hand as much as possible.
Text in Illustration
(c) Install SST to the fuel pump gauge retainer.
SST : 09808-14030
09808-01010
09808-01020
09808-01030
09808-01040
09808-01050
(1) Temporarily install plate and claw to the fuel pump gauge retainer.
(2) Press claw against the rib of the fuel pump gauge retainer, and tighten bolt.
(3) Install handle.
(d) While making sure that SST does not rise up, slowly turn handle and tighten until the mark on the fuel pump gauge retainer is within range A as shown in the illustration.
NOTICE:
* Be careful not to apply excessive downward force to SST, as this may damage the fuel pump or fuel tank.
* 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 bolt and install SST again.
4. CONNECT FUEL TANK VENT HOSE
Text in Illustration
(a) Connect the fuel tank vent hose and lock it by pushing in the retainer.
NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the charcoal canister outlet tube is inserted securely.
* Check that the charcoal canister outlet tube is securely connected by pulling on it.
5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Connect the fuel tank main tube sub-assembly to the fuel suction tube with pump and gauge.
(b) Install the fuel joint clip.
Text in Illustration
NOTICE:
* Make sure there is no damage to or foreign matter on the connecting surfaces.
* Check that the fuel tube joint is correctly and fully inserted.
* Check that the main joint clip is above the rib of the fuel tube joint.
* After installing the fuel tube joint, make sure the fuel tube joint will not come out.
* Do not damage any of the clips. If a clip is damaged, replace it.
6. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the fuel pump connector to the fuel suction tube with pump and gauge.
(b) Apply butyl tape to the location shown in the illustration, align the matchmarks, and install the rear service hole cover.
Text in Illustration
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
8. ADD FUEL
9. INSPECT FOR FUEL LEAK Testing and Inspection
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