Fuel Pump: Installation

1. Apply a light coat of gasoline to 2 new O-rings, and install them to the fuel pressure regulator.
   Fig 1: Identifying Fuel Pressure Regulator O-Rings

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2. Install the fuel pressure regulator to the fuel relief valve.

Fig 2: Installing Fuel Pressure Regulator To Fuel Relief Valve

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1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and jet pump to the fuel relief valve assembly.

Fig 3: Identifying Jet Pump O-Ring

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1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and fuel relief valve assembly to the fuel filter.

Fig 4: Identifying Fuel Relief Valve O-Ring

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1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and flange assembly to the fuel filter.

Fig 5: Identifying Flange Assembly O-Ring

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1. Install the fuel pump spacer to the fuel pump.
2. Apply a light coat of gasoline to a new seal, and install it to the fuel pump.
3. Install the fuel pump to the fuel filter.
   Fig 6: Locating Fuel Pump Spacer

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4. Connect the 2 connectors and terminal.

Fig 7: Locating Connectors And Terminal

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1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and No. 1 fuel sub-tank to the fuel filter with flange assembly.
   Fig 8: Locating O-Ring And No. 1 Fuel Sub-Tank

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2. Connect the jet pump nozzle to the No. 1 fuel sub-tank.
   Fig 9: Locating Jet Pump Nozzle

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3. Install a new E-ring.

Fig 10: Identifying E-Ring

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1. Set the fuel sender gauge to the No. 1 fuel sub-tank. Then slide the sender gauge downward to install it.
2. Connect the fuel sender gauge connector.

1. Install a new gasket onto the fuel tank.
   Fig 11: Installing Sender Gauge Assembly

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2. Connect the fuel hose with the clip.
3. Set the fuel suction tube to the fuel tank.
   NOTE:

   • Make sure that the fuel sender gauge arm does not bend.
   • Do not damage the No. 2 fuel hose.
   Fig 12: Installing Fuel Suction With Pump And Gauge Tube Assembly

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4. Align the protrusion of the fuel suction tube and the cutout of the fuel tank vent tube set plate.
5. While holding the fuel suction tube by hand, install the fuel tank vent tube to the fuel tank with the 8 bolts.

   Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

   Fig 13: Aligning Protrusion Of Fuel Suction Tube And Cutout Of Fuel Tank Vent Tube Set Plate

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6. Connect the fuel tube.
   1. Push the fuel tube joint in the plug of the fuel suction plate, then install the 2 tube joint clips.
   NOTE:

   • Check that there are no scratches or foreign objects on the connecting parts.
   • Check that the fuel tube joint is inserted securely.
   • Check that the tube joint clips are on the collars of the fuel tube joints.
   • After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
   • Be careful not to damage any clips. If a clip is damaged, replace it.

   Fig 14: Installing Tube Joint Clips

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7. Connect the fuel suction tube connector.

1. Install the No. 2 rear floor service hole cover with new butyl tape.
Fig 15: Identifying No. 2 Rear Floor Service Hole Cover
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1. Perform initialization (See INITIALIZATION ).

HINT:

Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.