TECHNICAL INSTRUCTIONS AURIS AURIS HYBRID COROLLA RUKUS ZELAS REPLACEMENT OF FUEL SUCTION PLATE 1. OPERATION FLOW CHART --------------------------------- 3 2. IDENTIFICATION OF AFFECTED VEHICLES ---------- 4 3. PREPARATION -------------------------------------------------- 6 4. WORK PROCEDURE ------------------------------------------- 16 1
Safety Precautions Be sure to observe the following precautions to prevent accidents and injuries. - Park the vehicle and chock the wheels. - If it is necessary to start the engine, perform the operation in a well ventilated area. - Before removing and reinstalling heavy parts such as the engine, transmission and differential using specified tools, check that there are no problems with the tools. - When working in a group of 2 or more, each person must work to ensure the safety of all team members. - To prevent burns and other injuries, use extra caution when handling parts that are subject to high temperatures, as well as rotating, sliding, or vibrating parts. - When lifting the vehicle using a jack, support it in the specified location using a safety stand. - When lifting the vehicle using a lift, lock the lift for safety. Also perform the following operation with care. Use of auto lift - Make absolutely certain that there are no other workers and no tools, parts, or other objects within the movable range of the lift. Also, be sure to announce all lift operations out loud (such as Raising the lift! and Lowering the lift! ) to alert other workers. - When raising or lowering the lift, pay attention to the positions of your arms, legs, and other body parts, and be extremely careful to prevent them from being caught in the lift. Use of brake cleaner - Use brake cleaner for appropriate purposes in accordance with instructions in the manual. - Do not use brake cleaner to remove dirt or stains from the engineer clothes and so forth, as it can catch on fire and cause serious burns. < Precautions > - Do not use brake cleaner near flames or fire. - Do not use large amounts of brake cleaner in a room where a fire is burning. - Do not keep brake cleaner in a place subject to high temperatures exceeding 40 C, such as a place subject to direct sunlight or near fire. - Do not put brake cleaner in fire. Edges - When handling the edges of parts and panels, wear protective gloves or apply protective tape to the edges to prevent injuries to your hands and fingers. 2
1. OPERATION FLOW CHART Check whether or not vehicle has an affected VIN or frame number. No No further action is required. Yes PREVENT FUEL LEAKS (Page 30) Drain fuel before replacing the fuel suction plate sub-assembly, if the fuel gauge displays that 3/4 or more of fuel is left in the fuel tank. (Page 87) REMOVE FUEL PUMP GAUGE RETAINER AND DETACH FUEL SUCTION TUBE ASSEMBLY (Page 35) The fuel suction tube assembly must be pressed down by the assisting worker while the fuel pump gauge retainer is loosened. Failure to do so will break the fuel tank. REPLACE FUEL SUCTION PLATE SUB-ASSEMBLY (Page 53) INSTALL FUEL SUCTION TUBE ASSEMBLY WITH NEW FUEL PUMP GAUGE RETAINER (Page 65) When the retainer is tightened approx. 90 degrees it will be slightly lifted due to improper thread engagement. In order to allow the retainer threads to engage with the fuel tank threads, press down on the retainer in accordance with the instructions. Tighten the retainer in a group of 2 workers, same as for removal of the retainer. RESTORE VEHICLE (Page 86) 3
2. IDENTIFICATION OF AFFECTED VEHICLES 2.1. COVERED VIN RANGE Model Name Model Code VIN Range WMI VDS VIS AURIS ZRE152 JTN KG56E 1053656~1053656 AURIS NRE150 JTN KH56E 1000104~1000307 AURIS NRE150 JTN KH58E 1000209~1000306 AURIS ZZE150 JTN KM56E 1000104~1005651 AURIS ZZE150 JTN KM58E 1000140~1005405 AURIS ZRE151 JTN KP56E 1015935~1015936 AURIS ZRE152 JTN KU52E 1007371~1105578 AURIS ZRE152 JTN KU56E 1002025~1182313 AURIS ZRE152 JTN KU58E 1007512~1139216 AURIS ZRE151 JTN KV56E 1000105~1018643 AURIS ZRE151 JTN KV58E 1000202~1016997 AURIS ZRE152 JTN KG56E J011456~J011456 AURIS NRE180 JTN KJ0JE J000104~J001406 AURIS ZRE181 JTN KP0JE J000106~J003238 AURIS ZRE181 JTN KP3JE J000102~J003237 AURIS ZRE182 JTN KU3JE J000105~J083524 AURIS ZRE152 JTN KU52E J000106~J001995 AURIS ZRE152 JTN KU56E J000122~J097173 AURIS ZRE152 JTN KU58E J000130~J000855 AURIS ZRE151 JTN KV56E J172110~J194326 AURIS ZRE151 JTN KV58E J028286~J028286 AURIS ZZE150 JTN KM56E 2000012~2013561 AURIS ZZE150 JTN KM58E 2000011~2012218 AURIS ZRE152 JTN KU52E 2000022~2020268 AURIS ZRE152 JTN KU56E 2000021~2019752 AURIS ZRE152 JTN KU58E 2000019~2020154 AURIS ZRE151 JTN KV56E 2000007~2065193 AURIS ZRE151 JTN KV58E 2000110~2065738 AURIS HYBRID ZWE150 SB1 KS56E E001002~E073377 COROLLA ZRE173 0001001~0002190 COROLLA ZZE142 7800000~7830789 COROLLA ZZE142 9BR BA42E 5000506~5158565 COROLLA ZZE142 9BR BA48E 5000508~5158587 COROLLA ZZE142 9BR BB48E 5000511~5000523 COROLLA ZZE141 9BR BC41E 5000503~5005530 COROLLA ZZE141 9BR BC42E 5000501~5009132 COROLLA ZRE172 9BR BU3HE 0001008~0043173 COROLLA ZRE142 9BR BU42E 4700023~4791123 COROLLA ZRE142 9BR BU48E 4700024~4791124 COROLLA ZRE172 9BR BUWHE 0001001~0043415 COROLLA NRE150 JTN BH56E 3500102~3500102 COROLLA ZZE150 JTN BM56E 3500101~3504414 COROLLA ZZE150 JTN BM58E 3500102~3505154 COROLLA ZRE151 JTN BV56E 3500101~3539074 COROLLA ZRE151 JTN BV58E 3500102~3539087 COROLLA NRE150 JTN BH56E J000106~J016104 COROLLA NRE150 JTN BH58E J000138~J016442 COROLLA ZZE150 JTN BM56E J000102~J013851 COROLLA ZZE150 JTN BM58E J000101~J013981 4
Model Name Model Code VIN Range WMI VDS VIS COROLLA ZRE151 JTN BP56E J062532~J085800 COROLLA ZRE152 JTN BU52E J000107~J064077 COROLLA ZRE152 JTN BU56E J000124~J108656 COROLLA ZRE152 JTN BU58E J000144~J027241 COROLLA ZRE151 JTN BV56E J000101~J223420 COROLLA ZRE151 JTN BV58E J000117~J223424 COROLLA ZRE153 JTN BZ56E J000101~J001037 COROLLA ZZE150 JTN BM56E 2000115~2013614 COROLLA ZZE150 JTN BM58E 2000083~2013615 COROLLA ZRE152 JTN BU52E 2000027~2020277 COROLLA ZRE152 JTN BU56E 2000011~2020276 COROLLA ZRE152 JTN BU58E 2000029~2020270 COROLLA ZRE151 JTN BV56E 2000019~2065748 COROLLA ZRE151 JTN BV58E 2000328~2065747 RUKUS AZE151 JTL KE4FE 1110667~1147096 RUKUS AZE151 JTL ZE4FE 1118212~1147067 RUKUS AZE151 JTL KE4FE J000107~J065424 RUKUS AZE151 JTL ZE4FE J000104~J065461 ZELAS AGT20 JTK JF5C7 3000108~3096409 ZELAS AGT20 JTK JF5C7 J000106~J015238 5
2.2. VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number is stamped on the vehicle body and on the certification label (name label) as shown in the illustration. A: Vehicle Identification Number B: Certification Label (Name Label) 6
3. PREPARATION 3.1. Replacement components <AURIS(ZRE15#, ZZE150), COROLLA(ZRE15#, ZZE150), RUKUS(AZE151)> Parts: Part Name Part No. Qty Remarks Fuel Suction Plate Kit 04004-84212 1 Fuel Suction Plate Sub-assembly 77024-12030 1 O-ring (Large) 90301-15024 1 For fuel pressure regulator O-ring (Medium) 90301-08020 1 For fuel pump O-ring (Small) 90301-04013 1 For fuel pressure regulator Fuel Tank Gasket Kit 04004-85552 1 Fuel Tank Gasket 77169-52030 1 For fuel suction plate Fuel Pump Gauge Retainer (White) 77144-52040 1 See Note 1 NOTE 1: Make sure to install the NEW WHITE fuel pump gauge retainer included in the SST kit. If needed, refer to the table above and order the WHITE fuel pump gauge retainer (part number: 77144-52040). 7
<AURIS(NRE150), COROLLA(NRE150)> Parts: Part Name Part No. Qty Remarks Fuel Suction Plate Kit 04004-53112 1 Fuel Suction Plate Sub-assembly 77024-12160 1 O-ring (Large) 90301-15024 1 For fuel pressure regulator O-ring (Medium) 90301-08020 1 For fuel pump O-ring (Small) 90301-04013 1 For fuel pressure regulator Fuel Tank Gasket Kit 04004-85552 1 Fuel Tank Gasket 77169-52030 1 For fuel suction plate Fuel Pump Gauge Retainer (White) 77144-52040 1 See Note 1 NOTE 1: Make sure to install the NEW WHITE fuel pump gauge retainer included in the SST kit. If needed, refer to the table above and order the WHITE fuel pump gauge retainer (part number: 77144-52040). 8
<AURIS(ZRE18#, NRE180)> Parts: Part Name Part No. Qty Remarks Fuel Suction Plate Kit 04004-85212 1 Fuel Suction Plate Sub-assembly 77024-12170 1 O-ring (Large) 90301-15024 1 For fuel pressure regulator O-ring (Medium) 90301-08020 1 For fuel pump O-ring (Small) 90301-04013 1 For fuel pressure regulator Fuel Tank Gasket Kit 04004-85552 1 Fuel Tank Gasket 77169-52030 1 For fuel suction plate Fuel Pump Gauge Retainer (White) 77144-52040 1 See Note 1 NOTE 1: Make sure to install the NEW WHITE fuel pump gauge retainer included in the SST kit. If needed, refer to the table above and order the WHITE fuel pump gauge retainer (part number: 77144-52040). 9
<AURIS HYBRID(ZWE150)> Parts: Part Name Part No. Qty Remarks Fuel Suction Plate Kit 04004-85347 1 Fuel Suction Plate Sub-assembly 77024-47090 1 O-ring (Large) 90301-15024 1 For fuel pressure regulator O-ring (Medium) 90301-08020 1 For fuel pump O-ring (Small) 90301-04013 1 For fuel pressure regulator Fuel Tank Gasket Kit 04004-85552 1 Fuel Tank Gasket 77169-52030 1 For fuel suction plate Fuel Pump Gauge Retainer (White) 77144-52040 1 See Note 1 NOTE 1: Make sure to install the NEW WHITE fuel pump gauge retainer included in the SST kit. If needed, refer to the table above and order the WHITE fuel pump gauge retainer (part number: 77144-52040). 10
<ZELAS(AGT20)> Parts: Part Name Part No. Qty Remarks Fuel Suction Plate Kit 04005-05421 1 Fuel Suction Plate Sub-assembly 77024-21060 1 O-ring (Large) 90301-15024 1 For fuel pressure regulator O-ring (Medium) 90301-08020 1 For fuel pump O-ring (Small) 90301-04013 1 For fuel pressure regulator Fuel Tank Gasket Kit 04004-85552 1 Fuel Tank Gasket 77169-52030 1 For fuel suction plate Fuel Pump Gauge Retainer (White) 77144-52040 1 See Note 1 NOTE 1: Make sure to install the NEW WHITE fuel pump gauge retainer included in the SST kit. If needed, refer to the table above and order the WHITE fuel pump gauge retainer (part number: 77144-52040). 11
<COROLLA (ZZE14#, ZRE142)> Parts: Part Name Part No. Qty Remarks Fuel Suction Plate Kit 04005-05912 1 Fuel Suction Plate Sub-assembly 77024-12240 1 O-ring (Large) 90301-15024 1 For fuel pressure regulator O-ring (Medium) 90301-08020 1 For fuel pump O-ring (Small) 90301-04013 1 For fuel pressure regulator Fuel Tank Gasket Kit 04004-85552 1 Fuel Tank Gasket 77169-52030 1 For fuel suction plate Fuel Pump Gauge Retainer (White) 77144-52040 1 See Note 1 NOTE 1: Make sure to install the NEW WHITE fuel pump gauge retainer included in the SST kit. If needed, refer to the table above and order the WHITE fuel pump gauge retainer (part number: 77144-52040). 12
<COROLLA (ZRE17#)> Parts: Part Name Part No. Qty Remarks Fuel Suction Plate Kit 04005-05012 1 Fuel Suction Plate Sub-assembly 77024-12180 1 O-ring (Large) 90301-15024 1 For fuel pressure regulator O-ring (Medium) 90301-08020 1 For fuel pump O-ring (Small) 90301-04013 1 For fuel pressure regulator Fuel Tank Gasket Kit 04004-85552 1 Fuel Tank Gasket 77169-52030 1 For fuel suction plate Fuel Pump Gauge Retainer (White) 77144-52040 1 See Note 1 NOTE 1: Make sure to install the NEW WHITE fuel pump gauge retainer included in the SST kit. If needed, refer to the table above and order the WHITE fuel pump gauge retainer (part number: 77144-52040). 13
3.2. Fuel Suction Plate Sub-assembly replacement Tools: Illustration Part Name Part No. Qty Remarks Claw 09808-01080 4 For removal and installation of fuel pump gauge retainer Plate 09808-01030 Component of the fuel pump gauge retainer tool (09808-14030) 1 For removal and installation of fuel pump gauge retainer Used in conjunction with supplied claws Fuel Tank Cap 09808-99050 1 For prevention of fuel vapor getting out of the fuel tank during work Recommended Tools: Illustration Part Name Part No. Qty Remarks - GTS (Global TechStream) - 1 For checking DTC - Torque Wrench - 1 - Vernier Caliper - 1 - Air Gun - 1 - Hose Plug (Small) 09053-1C220 2 For checking tightening torque For checking tightening of fuel pump gauge retainer For diffusion and ventilation of fuel vapor For prevention of fuel leaks - Butyl Tape Set - Φ6mm (thickness) x 700mm (length) per vehicle For reinstalling the rear floor service hole cover - Brake Cleaner - Appropriate quantity For cleaning sub tank 14
Equipment: Part Name Part No. Qty Remarks Tray - 2 Flashlight - 1 Protective Glasses - 1 For catching fuel For inspection of fuel pump For checking marks on fuel tank For disconnection of fuel tubes and hose Protective Tape - Appropriate quantity - Plastic Bag - Appropriate quantity For protecting fuel tube and Marker Pen - 1 For applying marks hose 15
4. WORK PROCEDURE <TABLE OF CONTENTS> A. WORK OUTLINE... 17 B. WHAT TO DO IF FUEL SUCTION TUBE ASSEMBLY IS NOT CENTERED IN SERVICE HOLE... 18 C. NOTES REGARDING FUEL SYSTEM REPLACEMENT WORK... 20 D. PRECAUTIONS FOR ALL OPERATIONS... 25 E. COMPONENTS... 27 F. PREVENT FUEL LEAKS... 30 G. REMOVE FUEL SUCTION TUBE ASSEMBLY... 35 H. REPLACE FUEL SUCTION PLATE SUB-ASSEMBLY... 53 I. INSTALL FUEL SUCTION TUBE ASSEMBLY... 65 J. RESTORE VEHICLE... 86 K. REFERENCE: DRAIN FUEL... 87 16
A. WORK OUTLINE Drain fuel before removing the fuel suction tube assembly if the fuel gauge displays that the remaining fuel level is 3/4 full or more. Otherwise, fuel will overflow from the fuel tank. (1) Replace the fuel suction plate sub-assembly of the fuel suction tube assembly. (2) The fuel suction tube assembly is fixed to the plastic fuel tank by the fuel pump gauge retainer (a plastic ring nut). (3) A high torque of up to approximately 200 N*m is required to loosen the fuel pump gauge retainer because the fuel tank, which is made of plastic, is swollen due to the fuel inside. Be sure to observe the instructions in this manual to ensure safety. 17
Not centered Slightly off-centered B. WHAT TO DO IF FUEL SUCTION TUBE ASSEMBLY IS NOT CENTERED IN SERVICE HOLE Check how much the fuel suction tube assembly is off-centered in the service hole, and follow the corresponding instructions shown below. 1. Set the tools onto the fuel pump gauge retainer under the service hole. 2. Use all 4 claws when turning the retainer in the first 90 degrees while loosening and in the last 90 degrees while tightening (higher torque is required in both situations), and remove a claw that comes into contact with the service hole and then turn the retainer with the remaining 3 claws. (For details, refer to the following page) Loosen the fuel tank bolts or fuel tank band bolts, and position the fuel tank. (Judge whether or not this is necessary after removal of the service hole cover) Refer to Repair Manual for instructions on FUEL > FUEL TANK 18
How to turn the fuel pump gauge retainer if a claw comes into contact with the service hole (Instructions shown below are for loosening) Higher torque is required in the first and last 90 degrees when the fuel pump gauge retainer is loosened and tightened, so all 4 claws must be used. (1) Claw comes into contact with the service hole when the retainer is loosened over 90 degrees (If the retainer cannot be turned over 90 degrees, remove and set all 4 claws on different positions so that the retainer can be turned over 90 degrees) (2) Remove the claw that came into contact with the service hole (If needed, slightly reverse the retainer) (3) Loosen the retainer another 90 degrees with the remaining 3 claws (4) Remove the claw that came into contact with the service hole (If needed, slightly reverse the retainer) (5) Install the removed claw to the position shown in the illustration (6) Turn the retainer by further 90 degrees (Retainer will be able to be turned with little effort) 19
<Make copies for use> C. NOTES REGARDING FUEL SYSTEM REPLACEMENT WORK When installing/uninstalling the fuel system components, keep safety first in mind and carefully observe the following instructions to avoid fire. Check each item in the appropriate section for each vehicle. 1. VENTILATION (a) Perform this work in a well-ventilated area (natural ventilation). DO NOT use exhaust fans or electric fans, because their motors might generate sparks. (b) Since it is possible for fuel vapor to build up, DO NOT work in or near a pit. (c) If fuel is spilled, use shop towels or similar material to quickly wipe it up and then use an air gun to diffuse the fuel vapor. (d) Shop towels and other materials that have come into contact with fuel should be dried in a well-ventilated area and then disposed of as appropriate. 2. DIFFUSION AND EXHAUST OF HIGHLY-CONCENTRATED FUEL VAPOR (a) Use compressed air frequently while working to prevent accumulation of high concentrations of fuel vapor. (b) When connecting battery terminals or operating switches, be sure to use compressed air to diffuse and ventilate fuel vapor. 3. USING GASOLINE AS AN ORGANIC SOLVENT (a) To prevent physical illness due to fuel vapor (organic solvent), use a gas mask for organic solvents as necessary in addition to ensuring natural ventilation. 20
<Make copies for use> 4. FLAMMABLE KEEP FIRE AWAY (a) When working on the fuel system, display the Flammable - Keep Fire Away sign. (Refer to the following page.) (b) Smoking is prohibited nearby. (c) Perform this work in an area where there are no flames due to nearby operation of welders, grinders, drills, electric motors, stoves, etc. (d) DO NOT use electrical devices such as operation indicators, because they can become hot and the operation of power switches can generate sparks. (e) DO NOT use iron or steel hammers while working, because they may generate sparks. (f) DO NOT perform the above operations or start engines even in adjacent stalls. 5. FIRE EXTINGUISHERS (a) Prepare fire extinguishers before starting this work. 6. PREVENTING STATIC ELECTRICITY (a) Keep the floor slightly wet but not wet enough to become slippery, to prevent the generation of static electricity. 7. HOLES IN THE FLOOR (a) If there are holes in the floor for lifts, etc., cover the gaps between service plates with tape, etc. (b) If fuel should get into a hole, remove the service plates to wipe away the fuel, and then use an air gun to dry the area until all fuel odor is gone. 21
22
<Make copies for use> 8. PREVENTING FUEL SPLATTER (a) When disconnecting piping, a slight amount of pressure remains in the pipe even after performing fuel spill prevention work. Use a shop towel, etc. to prevent the splattering of fuel. (b) Wear protective eyewear when performing this work. 9. PROTECTION WHEN DISCONNECTING FUEL HOSES AND TUBES (a) Protect disconnected fuel tubes inside plastic bags, to prevent fuel spills, scratches, and contamination. 10. PRECAUTIONS FOR CONNECTING FUEL PIPES (a) Carefully clean and inspect fuel pipes, to prevent leakage due to small scratches or foreign matter (dust, lint, rust, etc.) in joints. 11. PREVENTING FUEL FROM COMING INTO CONTACT WITH PARTS (a) DO NOT allow fuel to come into contact with rubber or leather parts. 23
<Make copies for use> 12. SAFETY MANAGER (a) Appoint a manger to be in charge of safety at all times. (b) The safety manager is in charge of constantly checking for flames and inspecting for safety around work areas. 13. SEPARATION OF WORK (a) This work must not be carried over to the next day. (b) In principle, work must not be interrupted. In cases where the interruption of work cannot be avoided, take care to perform all safety management procedures. 14. PREVENTING FUEL SPILLS INTO WATERWAYS (a) If a large volume of fuel is spilled, it must not be allowed to flow into waterways. It is extremely dangerous for fuel to spill into waterways or accumulate in sewage tanks, etc. 24
D. PRECAUTIONS FOR ALL OPERATIONS 1. PRECAUTIONS WHEN RAISING VEHICLE USING A LIFT OR JACK (a) Refer to the respective repair manual and follow the instructions within the Introduction section to ensure safety when working. (b) Ensure the safety of all personnel near the lift or jack, including yourself, before beginning work. Also announce all lift and jack operations out loud to prevent any personnel from being caught or harmed in any way. 2. WEAR PROTECTIVE GLASSES (a) Wear protective glasses when working under the vehicle or where there is any risk of flying parts or debris. 3. DO NOT USE BRAKE CLEANER AS STAIN REMOVER (a) Do not spray brake cleaner onto any clothes since it is a flammable solvent that vaporizes easily. Do not use it near cigarettes or stoves as this can cause serious burns and injuries. 4. AVOID BURNS (a) If the engine is hot, wear protective gloves to prevent burns. 25
5. VEHICLE PROTECTION (a) A fender cover, a grill cover, seat covers and protective tape etc. must be used to protect the vehicle from dirt or scratches. NOTE: The protective measures listed above may not be shown in some illustrations to allow easy identification of the work location and to make the illustrations simple and easy to read. 6. HANDLING OF REMOVED PARTS (a) Destroy or mark and store removed parts in a separate container so as to not be assembled again in error. (b) Check the removed parts when performing the completion inspection. NOTE: The parts shown in the illustration to the left are examples only and differ from the actual replacement parts. 7. DO NOT BREAK PARTS WHEN WORKING INSIDE ENGINE COMPARTMENT (a) Do not break parts by carelessly placing hands inside and leaning on the engine compartment while being preoccupied by work. 8. CHECK INSIDE ENGINE COMPARTMENT BEFORE ENGINE START-UP (a) Check that all necessary parts are installed. (b) Check that no tools or pieces of cloth are left inside the engine compartment. 26
E. COMPONENTS 27
28
29
F. PREVENT FUEL LEAKS 1. CHECK FOR DTCS (a) If a DTC(s) is displayed, record the DTC and the freeze frame data and perform the repairs as necessary. 2. RECORD CUSTOMER SETTINGS (a) When the battery cable is disconnected, the settings for the audio, air conditioning etc., may be reset. Therefore, make a note of the settings before disconnecting the cable from the negative (-) battery terminal. 3. TAKE MEASURES AGAINST SECURITY OF NAVIGATION SYSTEM (a) In some cases, a user password is set for restart of the system after disconnection of the power supply. Obtain confirmation of the customer in advance regarding conditions of the system at the time of returning the vehicle to the customer. 4. CHECK FUEL LEVEL (a) Check and record the remaining fuel level for confirming correct operation of the fuel sender gauge after replacement of the fuel suction plate sub-assembly. Drain fuel before removing the fuel suction tube assembly if the fuel gauge displays that the remaining fuel level is 3/4 full or more. Otherwise, fuel will overflow from the fuel tank. (Proceed to Section K. REFERENCE: DRAIN FUEL on page 87.) 5. ENSURE VENTILATION (a) Fully open all windows to prevent fuel vapor from condensing in the cabin. 30
6. RECORD SEAT POSITIONS 7. PROVIDE WORK SPACE (a) Fully recline the seatbacks of the driver and passenger seats forward and move each seat to the foremost position. 8. DISPLAY NO FIRES SIGN (a) For safety, attach the NO FIRES sign on the vehicle in a place where it can be clearly seen. (Use a copy of the sign on the next page.) 31
32
9. PROTECT VEHICLE INTERIOR (a) Protect the interior in order to prevent it from being damaged during removal/reinstallation of the seat. 10. PREVENT FUEL LEAKS Refer to Repair Manual for instructions on FUEL SYSTEM > PRECAUTION Seat config. II : The 2 front hooks of the rear seat cushion are engaged tight, and if the seat cushion is forcibly raised by holding an area far from the front hooks, the seat cushion frame may deform and this could cause the cushion pad to break. In order to prevent this, hold the area next to the front hooks when removing the seat cushion. 33
DO NOT contaminate the vehicle interior with the butyl tape on the service hole cover. (a) Cover the seat belts with a piece of cloth and temporarily fasten them to the rear side with tape, as shown in the illustration, to protect them from adhesion of the butyl tape. 11. REMOVE FUEL TANK CAP ASSEMBLY (a) Remove the fuel tank cap and relieve the pressure in the fuel tank. 12. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL Disconnect the negative (-) battery terminal cable to prevent sparks. For models with a HDD navigation system, wait at least 6 minutes before disconnecting the battery. It takes approximately 6 minutes for the system to save information and settings after the engine switch is turned off. 34
G. REMOVE FUEL SUCTION TUBE ASSEMBLY Drain fuel before removing the fuel suction tube assembly if the fuel gauge displays that the remaining fuel level is 3/4 full or more. Otherwise, fuel will overflow from the fuel tank. (Proceed to Section K. REFERENCE: DRAIN FUEL on page 87.) 1. APPLY PROTECTIVE TAPE (a) Apply protective tape along the edges of the rear floor service hole circumference as shown in the illustration to prevent injuries. 2. CLEAN TUBE AND HOSE JOINTS (a) Clean and remove any foreign material from the joints of the hose and tubes and their periphery, before disconnection of any hose or tubes. Otherwise, problems such as a clogging in the fuel system may occur. DO NOT use an air gun but use a vacuum cleaner to clean the specified area, to prevent dust from circulating inside the cabin. 35
3. DISCONNECT HOSE AND TUBES Be extremely careful NOT to injure yourself by the edges of the service hole. (a) ear protective glasses and use pieces of cloth to prevent fuel splashes when disconnecting the fuel tube. Fuel could spray out into the air due to residual pressure in the tube. (b) Disconnect the No. 1 charcoal canister outlet hose and No. 1 fuel evaporation tube. (c) Install hose plugs to the disconnected ends of the hose and tube to prevent entry of foreign material. (d) Fasten each hose plug with tape to prevent it from coming off. 36
(e) Disconnect the No. 2 fuel tank evaporation tube. (1) Using a thin slotted screwdriver, release the lock to disengage the tube. (2) Pull out the No. 2 fuel tank evaporation tube. (f) Cover the disconnected evaporation tube with a plastic bag to prevent damage and insertion of foreign material. 37
(g) Use enough pieces of cloth to prevent fuel from splashing, as up to approximately 100 cc of fuel may flow out from the fuel tube. (h) Disengage the clip from the fuel tank main tube by pushing it with a thin slotted screwdriver while disengaging the claws with a finger. (i) Disconnect the tube by pulling it straight up. DO NOT use any tools when disconnecting the fuel tube. Otherwise, the fuel tube may be damaged. (j) If the tube connector is stuck, push and pull it to disconnect. (k) Cover the disconnected tube with a plastic bag to prevent damage and insertion of foreign material. (l) Wrap pieces of cloth around the disconnected ends of the tubes covered with plastic bags, to make it easier to fasten the tubes and hose under the floor. 38
4. FASTEN TUBES AND HOSE (a) Insert the tubes and hose to the clearance under the floor as shown. (b) Fasten the tubes and hose securely in place with packing tape, as shown in the illustration. If tape does not stick due to a contamination, clean and degrease the floor surfaces and the fuel tank. Use packing tape that has strong adhesive force. DO NOT use masking tape as it does not have enough adhesive force. Fasten the disconnected tubes and hose in place as instructed. Otherwise, they may get caught in the tools and break, or a piece of cloth may get caught in the threads of the fuel pump gauge retainer, when rotating the retainer. 39
5. MAKE MATCH MARKS ON FUEL SUCTION TUBE ASSEMBLY AND PROTECTIVE TAPE ON FLOOR (a) Make match marks with the straight line on the fuel suction tube assembly and protective tape on the floor, as shown in the illustration. (The match mark can be applied to any point on the circumference of the circle.) The fuel suction tube assembly has 2 protruded portions that engage with the 2 cutouts in the fuel tank. DO NOT remove or install the fuel pump gauge retainer if the fuel suction tube assembly is not securely engaged with the fuel tank, as the assembly may rotate together with the retainer and cause damage. Make sure to make the match marks to ensure that the fuel suction tube assembly is installed in the proper position, in order to prevent the assembly from rotating together with the retainer. 40
6. MAKE MARKS ON PROTECTIVE TAPE ON FLOOR WHERE MARKS ON FUEL TANK ARE APPLIED (a) Make 2 The marks on the protective tape on the floor at the 2 points as show in the illustration below. The marks indicate the position where the area with smaller clearances between the ribs comes after completion of tightening. marks will be used only for installation of the fuel pump gauge retainer. However, make marks on the protective tape on the floor in this step, as match marks are applied in the previous step. Use a flashlight when checking the marks on the fuel tank. DO NOT use work lights as they may cause fires due to sparks and heat. 41
HOW TO SET TOOLS ON FUEL PUMP GAUGE RETAINER Proceed to Page 42 for Details A high torque of up to approximately 200 N*m is required to loosen the fuel pump gauge retainer because the fuel tank, which is made of plastic, is swollen due to the fuel inside. Be sure to observe the instructions in this manual and ensure safety during work. NOTE: In this instruction manual, the setting procedure for the 4 claws is divided into 2 steps, as it is difficult to set the 4 claws onto the retainer in one step due to tilting of the claws. 42
7. PREPARE FUEL PUMP GAUGE CLAMPING CLAWS (a) Remove the bolt, and then separate the spacer. The spacer will not be used in the following procedures. DO NOT lose the removed spacers. (b) Return the bolt and temporarily tighten it. (c) Stretch the claw as wide as possible. (d) Tighten the bolt. DO NOT loosen the adjustment bolts until completion of the operations. 8. PROTECT FLOOR (a) Place pieces of cloth on the floor around the rear floor service hole, as shown in the illustration, to absorb any fuel leakage. 9. SET TOOLS TO FUEL PUMP GAUGE 43 RETAINER (a) Remove the head bolt from the 4 claws. (b) Temporarily set the 4 claws evenly spaced along the outer circumference of the retainer as shown in the illustration. DO NOT set any claws onto the area where the clearances between the ribs are small. The claw cannot be properly set here. It is acceptable for the claws to be tilted at an angle in this step.
(c) Attach the clamps of 2 claws to the fuel pump gauge retainer using the following procedure. (1) Set the claw over the ribs on the upper surface of the retainer, as shown. (2) Insert the lower clamp edge to the clearance between the lower surface of the retainer and the fuel tank. (d) Place the plate which is included in the SST kit on the 2 claws which were set in the previous step, and then temporarily tighten the 2 clamp head bolts. Component of the SST kit (09808-14030), Part No. 09808-01030 (e) Attach the remaining 2 claws to the retainer using the same procedure as for the other 2 claws. 44
(f) Align the center of the SST plate with the center of the retainer, and temporarily tighten the remaining 2 head bolts. (g) Confirm that the 4 claws are securely installed on the retainer, and then tighten the 4 head bolts. Make sure that no claw is tilted at an angle. If tilted, the claw may disengage while removing the retainer. 45
10. REMOVE FUEL PUMP GAUGE RETAINER (a) Loosen the retainer by slowly rotating it approximately 90 degrees. NOTE: A spinner handle or SST T-type handle can be used as the claws are holding the retainer by clamping. DO NOT lean or press on the tools as the claws are holding the retainer by clamping. If pressed, the retainer will be pressed against the fuel pump, making it harder to remove the retainer due to application of additional force. This may result in damage to the components. Rotate the handle while keeping it vertical to the plate. DO NOT rotate the handle at an angle as this may cause the tools to be removed. DO NOT pull the handle with a large force or use an impact wrench as they may cause damage to the components. DO NOT allow the tubes and hose, which were fastened below the floor, to get caught in the tools. 46
(b) Observe the following cautions and instructions to ensure that the retainer is loosened properly. The spring inside the fuel suction tube assembly presses the sub tank against the bottom surface of the fuel tank. Thus in reaction, an upward force is exerted. DO NOT rotate the retainer when the fuel suction tube assembly is not firmly engaged with the fuel tank. The assembly may rotate together with the retainer and be damaged. (c) After loosening the retainer by rotating it 90 degrees in step (a), the main worker must continue to slowly rotate it while the assisting worker presses the fuel suction tube assembly against the fuel tank, keeping the match marks aligned. To prevent fingers from being pinched, both workers must announce all operation out loud and work in cooperation. DO NOT allow the tubes and hose, which were fastened under the floor, to get caught in the tools. Rotate the retainer approximately one and a half turn in total to disengage the threads. Be extremely careful and rotate the retainer slowly as you cannot feel that the threads are becoming disengaged until immediately before they disengage. 47
(d) Remove the retainer together with the tools from the vehicle. If the retainer cannot be removed with the tools attached (the service hole interferes with the tools), separate the tools from the retainer. (e) Remove the tools from the retainer. (f) Mark the removed retainer and then store it in a separate container so as not to reinstall it in error. 11. REMOVE FUEL SUCTION TUBE ASSEMBLY The fuel suction tube assembly cannot be pulled straight out from the fuel tank due to its complex configurations. Observe the instructions and be extremely careful when removing the assembly. Otherwise, parts may break and/or fuel may be spilt inside the cabin. (a) Prepare a tray to place the fuel suction tube assembly immediately after removing it from the fuel tank. Make sure to prepare the tray, as remaining fuel may continue to leak out from the fuel suction tube assembly. 48
(b) Gently pull out the upper half of the fuel suction tube assembly. DO NOT bend the sender gauge arm by allowing the float to interfere with other parts. If fuel remains in the sub tank, tilt the fuel suction tube assembly before pulling it out from the fuel tank to drain the remaining fuel. Otherwise, fuel may spill on the floor. (c) Slide the upper half of the fuel suction tube assembly to the side, and bring the lower half of the fuel suction tube assembly to come to the center of the fuel tank hole. 49
(d) Pull out the lower half of the fuel suction tube assembly as shown below, to prevent it from being stuck in the fuel tank. DO NOT try to forcibly pull out the fuel suction tube assembly when it is stuck, as it may become broken apart. 50
(e) Gently pull out the fuel suction tube assembly until the sender gauge float touches the upper surface of the tank. DO NOT forcibly pull out the fuel suction tube assembly as the sender gauge arm may bend. (f) Tilt the fuel suction tube assembly while pulling it out from the fuel tank, and then place it in the tray right after it is removed. Make sure to place the fuel suction tube assembly in the tray right after taking it out from the fuel tank, as remaining fuel may continue to leak out. 51
12. REMOVE GASKET (a) Remove the gasket from the fuel tank, destroy the removed gasket and store it in a separate container so as not to reinstall it in error. 13. COVER FUEL TANK (a) In order to prevent fuel vapor from getting out, install the fuel tank cap. 52
H. REPLACE FUEL SUCTION PLATE SUB-ASSEMBLY 1. DRAIN FUEL (a) Drain the fuel from the fuel suction tube assembly by tilting it over the tray as shown in the illustration. 2. REMOVE FUEL SENDER GAUGE ASSEMBLY (THIS WILL BE REINSTALLED) AND HARNESS (a) Disconnect the 3 connectors. (b) Disengage the wire harnesses from the 3 clamps. DO NOT damage the claws. Disengage the wire harnesses one by one, to avoid damage to the wire harness covers. 53
(c) Disengage the claw, and then remove the sender gauge by sliding it in the direction shown in the illustration. DO NOT bend the sender gauge arm. 3. REMOVE FUEL PUMP (THIS WILL BE REINSTALLED) (a) Disengage the claws and disconnect the hose by disengaging the connecting portion shown in the illustration. (b) Disengage the hose from the claw. (c) Disengage the connecting portion shown in the illustration from the sub tank, by pulling it upward. 54
(d) Disengage the 2 claws and remove the fuel filter and fuel pump from the sub tank. DO NOT damage the claws. (e) Disengage the 2 claws and remove the fuel suction support. DO NOT damage the claws. (f) Disengage the 5 claws and remove the fuel pump from the fuel suction plate sub-assembly. DO NOT damage the claws. DO NOT drop the fuel pump. If dropped, DO NOT reinstall it as it may malfunction. 55
(g) Type A: (1) Remove the O-ring. (2) Destroy the removed O-ring and then store it in a separate container so as not to reinstall them in error. A NEW O-ring will be installed to the fuel pump, so remove the existing O-ring. Otherwise, problems will occur due to the extra O-ring. (h) Type B: (1) Remove the O-ring and spacer from the fuel pump. DO NOT dispose of the spacer as it will be reused. A NEW O-ring will be installed to the fuel pump, so remove the existing O-ring. Otherwise, problems will occur due to the extra O-ring. (i) Destroy the removed O-ring and then store it in a separate container so as not to reinstall it in error. 56
4. REMOVE SUB TANK (THIS WILL BE REINSTALLED) (a) Disengage the 2 claws and remove the sub tank. Be sure to disengage the upper claws as shown, as claws are also provided on the lower side. DO NOT damage the claws. DO NOT remove the spring. 5. REMOVE FUEL PRESSURE REGULATOR (THIS WILL BE REINSTALLED) (a) Using a screwdriver with its tip wrapped in protective tape, gently pry out the fuel pressure regulator from the housing. DO NOT try to forcibly pry out the fuel pressure regulator, as it could cause damage. (b) Remove the fuel pressure regulator by pulling it downward by hand. DO NOT use any tools as it could cause damage. (c) Mark and then store the removed fuel suction plate sub-assembly in a separate container so as not to reinstall it in error. 57
(d) Remove the 2 O-rings. (e) Destroy the removed O-rings and then store them in a separate container so as not to reinstall them in error. DO NOT remove the C-ring, filter or spacer shown in the illustration. If accidentally removed, reinstall them by referring to the illustration. 6. PREPARE NEW FUEL SUCTION PLATE SUB-ASSEMBLY NOTE: Check that the NEW fuel suction plate sub-assembly has no cracks or other defects. 58
7. REINSTALL FUEL PRESSURE REGULATOR (a) Apply gasoline to 2 NEW O-rings and install them to the fuel pressure regulator. (b) Push the filter and C-ring in the direction of the arrow in the illustration as far as they can go. (c) Apply gasoline to the 2 installed O-rings again. (d) Insert the fuel pressure regulator straight into the NEW fuel suction plate sub-assembly until it stops (no gap is present between them). 8. INSTALL SUB TANK TO NEW FUEL SUCTION PLATE SUB-ASSEMBLY DO NOT disconnect the corrugated hose from the NEW fuel suction plate sub-assembly. If disconnected, DO NOT install the fuel suction plate sub-assembly but replace it with a NEW one as the hose cannot be reconnected. DO NOT damage the hose by pulling, twisting, or bending. 59
(a) Clean the sub tank using a brake cleaner. (b) Set the spring and the 2 rails in place. (c) Engage the 2 claws. (d) Push and pull the fuel suction plate sub-assembly and sub tank to confirm that they are sliding smoothly against each other without sticking. 60
9. REINSTALL FUEL PUMP DO NOT drop the fuel pump. If dropped, DO NOT reinstall it but replace it with a new one, as it may malfunction. Make sure to install a NEW O-ring as instructed. Otherwise, the engine starting problems may result due to fuel pressure leakage. (a) Type A: (1) Apply gasoline to a NEW O-ring, and then temporarily place it on the convex portion as shown the illustration with a thin slotted screwdriver. (2) Push the New O-ring into the convex portion as far as possible. Install the O-ring and spacer to the fuel pump (protruded portion). If the O-ring is not in place, fuel pressure will leak and this will cause engine start problems. (b) Type B: (1) Apply gasoline to a NEW O-ring. Then install the spacer and the NEW O-ring onto the protruded portion of the fuel pump as shown in the illustration. The spacer can be reinstalled facing either direction. Install the O-ring and spacer to the fuel pump (protruded portion). If the O-ring is not in place, fuel pressure will leak and this will cause engine start problems. 61
(c) Apply gasoline to the NEW O-ring again, and then reinstall the fuel pump to the fuel suction plate sub-assembly. (d) Engage the 5 claws by pushing the fuel pump and sub tank against each other. (e) Engage the 2 claws to install the fuel suction support. DO NOT damage the claws. (f) Re-engage the 2 claws. DO NOT damage the claws. 62
(g) Connect the portion shown in the illustration to the sub tank by pushing it downward. Push the part downward as far as possible so that it is firmly engaged. (h) Fasten the hose with the claw. (i) Engage the claw. 10. REINSTALL FUEL SENDER GAUGE ASSEMBLY (a) Install the fuel sender gauge by sliding it in the direction of the arrow and then engaging the claw. DO NOT bend the sender gauge arm. (b) Connect the 3 connectors. 63
11. ENGAGE WIRE HARNESSES WITH 3 CLAMPS DO NOT damage the claws. Engage the wire harnesses one by one, to avoid damage to the wire harness covers. (a) Clamp the 2 wire harnesses properly so that they are not too tight or loose at the terminals. (b) Fasten all wire harnesses with the upper clamp so that they are not too tight or loose near the upper connector, as shown in the illustration. DO NOT clamp over the wire harness covers. (c) Clamp the wire harnesses properly so that they are not too tight or loose in the area shown in the illustrations below. The type of wire harness is different depending on the model specifications as shown below. Make sure that the wire harness is away from the spring and any part of the wire harness is not caught in the spring. 64
I. INSTALL FUEL SUCTION TUBE ASSEMBLY 1. REMOVE FUEL TANK CAP 2. CLEAN FUEL TANK (a) Wipe and clean the upper surface of the fuel tank where a NEW gasket will be installed. 65
3. MAKE MARK ON PROTECTIVE TAPE ON FLOOR AT FUEL TANK THREAD STARTING POINT (a) Visually check the thread starting point of the fuel tank, and make a mark on the protective tape on the floor. 4. INSTALL NEW GASKET (a) Install a NEW gasket to the fuel tank. 66
5. REINSTALL FUEL SUCTION TUBE ASSEMBLY (a) Make sure that the fuel suction tube assembly is in the correct orientation and hold it in place. DO NOT change the orientation of the fuel suction tube assembly by rotating it through a large angle, after inserting the lower half of the fuel suction tube assembly in the fuel tank. This may bend the sender gauge arm. (b) Insert the fuel suction tube assembly to the fuel tank in the reverse order of removal. DO NOT bend the sender gauge arm by allowing the float to interfere with other parts. DO NOT touch or move the wire harnesses while inserting the fuel tube assembly. (c) Slide the upper half of the fuel suction tube assembly to the side, and then insert it to the fuel tank. 67
6. SET CLAWS AND PLATE TO NEW FUEL PUMP GAUGE RETAINER If the service hole does not allow the fuel pump gauge retainer to pass with the tools attached, set the tools to the retainer in the space under the service hole. (a) Remove the head bolt from the 4 claws. (b) Temporarily set the 4 claws evenly spaced along the outer circumference of a NEW fuel pump gauge retainer as shown in the illustration. Make sure that the fuel pump gauge retainer is NEW. DO NOT set any claws onto the area where the clearances between the ribs are small. The claw cannot be properly set here. It is acceptable for the claws to be tilted at an angle in this step. (c) Attach the clamps of 2 claws to the fuel pump gauge retainer using the following procedure. (1) Set the claw over the ribs on the upper surface of the retainer, as shown. (2) Engage the lower clamp edge under the retainer. (d) Set the plate which is included in the SST kit on the 2 claws which were set in the previous step, and then temporarily install it with the 2 bolts. Component of the SST kit (09808-14030), Part No. 09808-01030 68
(e) Set the remaining 2 claws to the retainer using the same procedure as for the other 2 claws. (f) Align the center of the SST plate with the center of the retainer, and temporarily tighten the remaining 2 head bolts. (g) Confirm that the 4 claws are securely installed on the retainer, and then tighten the 4 head bolts. Make sure that no claw is tilted at an angle. If tilted, the claw may disengage while installing the retainer. 69
7. MAKE MATCH MARKS ON FUEL SUCTION TUBE ASSEMBLY AND FLOOR (a) Engage the protruded portions of the fuel suction tube assembly with the cutouts in the fuel tank. (b) Make match marks with the straight line on the floor and the fuel suction tube assembly, as shown in the illustration. The match marks applied before removal of the retainer is gone because the fuel suction plate sub-assembly has been replaced with a NEW one. DO NOT make the match marks in positions where they will be hidden after installation of the NEW retainer. 8. REMOVE PROTECTIVE CAPS (a) Remove the 4 protective caps from the fuel suction plate sub-assembly, if installed. They may interfere with the claws when tightening the NEW retainer. 70
9. WORK OUTLINES FOR TIGHTENING FUEL PUMP GAUGE RETAINER (a) Press down on the retainer. When the NEW retainer is tightened, the rear left of the retainer will be slightly lifted due to improper engagement of the threads caused by the swelling of the fuel tank (made of plastic). DO NOT try to further tighten the retainer with the threads improperly engaged. The threads in the retainer may become completely disengaged from the threads in the fuel tank or the retainer may become installed to the fuel tank at an angle. Make sure to press down on the retainer in accordance with the instructions in this manual before further tightening the retainer, to ensure proper installation. Place NEW Tighten Rear left of Press down on Threads are retainer with retainer by retainer will rear left of engaged its thread rotating it be slightly retainer properly starting point through lifted without any aligned with approx. 90 tilting of mark degrees retainer 71
(b) Tighten the retainer. (Proceed to page 73 for detailed instructions.) The retainer is not installed by tightening it to a specified torque but is installed by tightening it through the specified angle. Work in a group of 2 and install it by turning it through approximately one and a half turn. 72
10. CONFIRM PROPER ENGAGEMENT OF FUEL PUMP GAUGE RETAINER THREADS (a) Confirm that the NEW gasket is properly installed on the fuel tank. Make sure to properly install the gasket on the fuel tank and be extremely careful not to move it after installation. Otherwise, the gasket may get caught in the parts but will become unable to be seen by eyes. (b) Align the protruded portions of the fuel suction tube assembly with the cutouts in the fuel tank, and press the assembly against the tank and hold it in place. DO NOT allow the gasket to get caught in the components. DO NOT stop pressing the fuel suction tube assembly until instructed to do so (until the retainer is rotated through 450 degrees in total). DO NOT tighten the retainer unless the match marks on the fuel suction tube assembly and protective tape on the floor are aligned. The assembly will rotate together with the retainer and result in damage. (c) While the assisting worker is pressing the fuel suction tube assembly against the fuel tank, the main worker must align the NEW retainer s thread starting point (the area with smaller clearances between the ribs) with the mark on the floor that indicates the starting point of the retainer threads (starting point of tightening). 73
11. TIGHTEN FUEL PUMP GAUGE RETAINER (a) While the assisting worker is pressing the fuel suction tube assembly against the fuel tank, the main worker must gently tighten the retainer by rotating it through approximately 90 degrees. To prevent fingers from being pinched, both workers must announce all operation out loud and work in cooperation. Ensure that the fuel suction tube gauge assembly is firmly pressed against the fuel pump. Otherwise, the assembly will rotate together with the retainer as it will be disengaged from the fuel tank, and become damaged. DO NOT allow the tubes and hose, which were fastened under the floor, to get caught in the tools. 74
(b) After the retainer is rotated through approximately 90 degrees, quickly press down on the rear left of the retainer to ensure that the threads are properly engaged. How to Press Down On the Retainer: Place your hand on the rear left of the retainer, where it is slightly lifted, and make sure to press down quickly. DO NOT press down on the retainer slowly. The tank may become deformed and the threads will not be engaged properly. DO NOT try to engage the threads by striking the retainer as it may damage the components. NOTE: If the retainer cannot be pressed down due to interference with the tools, adjust the positions of the tools. (c) Confirm that the engagement sound is heard and that the retainer is not tilted. Also, the components should not be deformed by pressing down on the retainer. 75
(d) Using a vernier caliper, confirm that the threads are engaged properly without any tilting of the retainer. Take measurements to confirm that the retainer is not set at an angle, as it could cause fuel leaks. (1) Using a vernier caliper, measure the dimensions between the upper surface of the fuel tank and the bottom surface of the retainer as shown. (2) Take measurements at the 3 locations on the outer circumference of the retainer, near the indicated areas. (3) Compare the 3 results to check whether the retainer is installed properly. Standard: Differences between the measured values are within 3 mm [0.12 in.]: The retainer is properly set. Differences between the measured values are approximately 6 mm [0.24 in.]: The retainer is tilted as one thread (6 mm [0.24 in.]) is not engaged. Remove the retainer, reinstall the gasket, align the protruded portions of the fuel suction tube assembly with the cutouts in the fuel tank, and then retighten the retainer. 76
(e) While the assisting worker is pressing the fuel suction tube assembly against the fuel tank, the main worker must gently tighten the retainer through 360 degrees. (The retainer will be additionally rotated through an angle of approximately 90 degrees in a later step) To prevent fingers from being pinched, both workers must announce all operation out loud and work in cooperation. Ensure that the fuel suction tube assembly is firmly pressed against the fuel pump. Otherwise, the assembly will rotate together with the retainer as it will be disengaged from the fuel tank, and become damaged. DO NOT allow the tubes and hose, which were fastened under the floor, to get caught in the tools. 77
(f) Stop pressing the fuel suction tube assembly after turning the retainer through 450 degrees in total. The assembly does not be disengaged from the fuel tank after the retainer is turned through 450 degrees. (g) Gently rotate the retainer until the thread starting point comes between the marks that indicate that the retainer is completely installed. DO NOT lean or press on the tools as the claws are holding the retainer by clamping. If pressed, the retainer is pressed against the fuel pump, making it harder to remove the retainer due to application of additional force. This may result in damage to the components. Rotate the handle while keeping it vertical to the plate. DO NOT rotate the handle at an angle as this may cause the tools to be removed. DO NOT pull the handle with a large force or use an impact wrench as they may cause damage to the components. DO NOT allow the tubes and hose, which were fastened below the floor, to get caught in the tools. (h) Remove all tools from the retainer. 78
12. CHECK FUEL PUMP GAUGE RETAINER INSTALLATION CONDITIONS If the match marks are not aligned or the retainer is installed at an angle, fuel will leak. (a) Check that the match marks are aligned. (1) Check that the match mark of the fuel suction tube assembly is aligned with the other match mark provided on the floor. (b) Check that the fuel pump gauge retainer is not installed at an angle. (1) Using a vernier caliper, measure the dimensions between the upper surface of the fuel tank and the bottom surface of the retainer as shown. (2) Take measurements at the 3 locations on the outer circumference of the retainer, near the indicated areas. (c) Compare the 3 results to check whether the retainer is installed properly. Standard: Differences between the measured values are within 3 mm [0.12 in.]: The retainer is properly installed. Differences between the measured values are approximately 6 mm [0.24 in.]: One thread (6 mm [0.24 in.]) is not engaged. Remove the retainer and reinstall it. 79
13. RECONNECT TUBES AND HOSE (a) Remove the plastic bag from the fuel tank main tube. (b) Remove the plastic bag from the fuel tank main tube. (c) Check the tube connector and tube for any damage or adhesion of foreign material. DO NOT reuse the tube but replace it with a NEW one if damaged. (d) Reconnect the tube by pushing it straight down, and engage the clip. DO NOT engage the clip before reconnecting the fuel tube. Otherwise, the tube will not be fastened securely. (e) Push and pull the tube and connector to confirm that they are securely connected. 80
(f) Remove the plastic bag from the No. 2 fuel tank evaporation tube. (g) Check the tube connector and tube for any damage or adhesion of foreign material. DO NOT reuse the tube but replace it with a NEW one if damaged. (h) Reconnect the tube and then engage the lock by pushing it as shown in the illustration. (i) (j) Remove the hose plugs from the No. 1 charcoal canister outlet hose and No. 1 fuel evaporation tube. Reconnect the hose and tube. 14. REMOVE AND APPLY NEW BUTYL TAPE DO NOT injure yourself by the sharp edges or burrs on service hole and cover. Make sure to completely seal the service hole with butyl tape. Otherwise, water such as rains could enter the cabin. (a) Remove the protective tape which may interfere when removing or applying of the butyl tape. 81