RM38T0EC _51 Engine / Hybrid System _144959 M20F-FXS, M20G-FXS FUEL _0604273 FUEL PUMP A

M20F-FXS, M20G-FXS FUEL  FUEL PUMP  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A545573N01
4.719,1.635 5.052,1.635 false 5.885,2.438 6.219,2.438 false 1.5,2.781 1.25,2.417 1.25,2.417 1.083,2.417 false 5.854,4.042 6.188,4.042 false 5.823,3.656 6.156,3.656 false 2.979,4.458 3.313,4.458 false 2.083,3.75 2.417,3.75 false 2.198,2.333 2.531,2.333 false 1.208,1 1.208,1.333 false 6.5,0.24 6.833,0.24 false 6.458,0.656 6.792,0.656 false 5.698,4.51 6.031,4.51 false 5.5,3.24 5.833,3.24 false 3.583,3.188 3.583,3.583 false 6.427,1 6.76,1 false 6.167,0.073 6.646,0.396 0.479,0.323 18 false 11 6.104,0.49 6.448,0.844 0.344,0.354 18 false 10 4.531,1.458 4.875,1.813 0.344,0.354 18 false 9 6.24,3.469 6.583,3.823 0.344,0.354 18 false 5 6.25,3.854 6.594,4.208 0.344,0.354 18 false 4 0.865,2.208 1.208,2.563 0.344,0.354 18 false 8 1.052,1.385 1.396,1.74 0.344,0.354 18 false 12 3.573,3.615 3.917,3.969 0.344,0.354 18 false 6 1.813,3.583 2.156,3.938 0.344,0.354 18 false 1 6.281,2.323 6.438,2.521 0.156,0.198 10 false ● 3.365,4.354 3.521,4.552 0.156,0.198 10 false ● 6.313,4.344 6.656,4.698 0.344,0.354 18 false 2 2.813,2.177 3.156,2.531 0.344,0.354 18 false 3 5.875,3.063 6.219,3.417 0.344,0.354 18 false 7 5.667,0.823 6.458,1.135 0.792,0.313 18 false 13, 14

Procedure Part Name Code
Z101186

Z101188

Z101187

1 FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 77020A (Click here) - -
2 FUEL PUMP GAUGE RETAINER 77144 (Click here) - -
3 FUEL TANK MAIN TUBE SUB-ASSEMBLY 77209F (Click here) - -
4 NO. 4 FUEL TUBE CLAMP 77289C - - -
5 FUEL GAUGE WIRE 82412 - - -
6 FUEL TANK VENT HOSE SUB-ASSEMBLY 77404A (Click here) - -
7 NO. 1 FUEL TUBE CLAMP 77285J - - -
8 FUEL TANK PRESSURE SENSOR (VAPOR PRESSURE SENSOR) 89461 (Click here) - -
9 REAR FLOOR SERVICE HOLE COVER 58325M (Click here) - -
10 CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL - - - -
11 CHECK FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK - (Click here) - -
12 REAR SEAT ASSEMBLY - - - -
13 INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL - - - (Click here)
14 PERFORM INITIALIZATION - - - (Click here)

● Non-reusable part - -

PROCEDURE

Hide 77020A 1.INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

a.
A545583C01
3.958,1.208 3.792,1.177 false 5.115,1.01 4.917,1.281 true 1.927,3.063 2.104,3.271 true 3.115,2.875 3.969,3.281 3.969,3.281 4.063,2.833 true 3.615,1.063 3.802,1.219 0.188,0.156 10 false *a 4.823,1.302 5.01,1.479 0.188,0.177 10 true *b 2.125,3.208 2.313,3.365 0.188,0.156 10 true *a 3.938,3.302 4.125,3.458 0.188,0.156 10 true *b 0.229,0.031 0.51,0.385 0.281,0.354 18 false i 3.844,0.031 4.125,0.385 0.281,0.354 18 false ii 1.708,2.01 1.99,2.365 0.281,0.354 18 false iii
*a Protrusion *b Notch


i.

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


ii.

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

NOTICE:
·

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

·

Make sure the horizontal angle of the fuel suction plate sub-assembly is less than 90°.

·

To avoid applying excessive force to the tip of the fuel sender gauge assembly, tilt the fuel sub-tank sub-assembly diagonally and insert it into the fuel tank assembly as shown in the illustration.


A545584C01
1.771,0.958 1.875,0.76 1.875,0.76 2.094,0.76 false 1.813,2.01 1.99,1.854 1.99,1.854 2.198,1.854 true 1.729,2.354 2.073,2.354 true 5.979,2.438 6.25,2.333 6.25,2.333 6.417,2.333 true 5.802,1.542 5.917,1.292 5.917,1.292 6.167,1.292 false 5.917,2.198 6.073,1.99 6.073,1.99 6.281,1.99 true 6.427,2.229 6.677,2.406 0.25,0.177 10 false *1 2.219,1.75 2.438,1.938 0.219,0.188 10 false *2 2.125,0.667 2.354,0.854 0.229,0.188 10 false *3 0.635,0.51 0.875,0.75 0.24,0.24 10 false *a 2.104,2.26 2.344,2.448 0.24,0.188 10 false *1 6.302,1.896 6.49,2.094 0.188,0.198 10 false *2 6.177,1.188 6.448,1.385 0.271,0.198 10 false *3
*1 Fuel Sender Gauge Assembly *2 Fuel Sub-tank Sub-assembly
*3 Fuel Suction Plate Sub-assembly - -
*a 90° - -




iii.

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



Hide 77144 2.INSTALL FUEL PUMP GAUGE RETAINER

a.
A545651C01
5.406,3.927 5.083,3.927 true 4.865,3.99 4.542,3.99 true 0.74,4.677 1.094,4.479 true 2.208,4.031 2.083,3.792 true 2.604,3.469 2.063,3.469 true 1.688,2.833 1.354,2.833 true 5.792,0.271 5.583,0.167 true 2.479,3.823 2.219,3.656 true 6.135,1.458 5.635,1.458 true 5.542,2.052 5.656,1.771 true 6.5,2.375 6.479,2.26 true 5.26,0.917 4.885,0.917 true 5.927,0.75 5.552,0.75 true 0.552,4.583 0.729,4.75 0.177,0.167 10 true *a 2.177,4.083 2.333,4.26 0.156,0.177 10 true *c 2.625,3.385 2.802,3.552 0.177,0.167 10 true *d 5.365,0.073 5.542,0.229 0.177,0.156 10 true *e 4.354,3.896 4.521,4.073 0.167,0.177 10 true *g 5.458,3.813 5.625,3.99 0.167,0.177 10 true *f 1.146,2.729 1.323,2.896 0.177,0.167 10 true *d 2.542,3.76 2.719,3.927 0.177,0.167 10 true *b 6.146,1.354 6.323,1.521 0.177,0.167 10 true *d 5.458,2.042 5.646,2.219 0.188,0.177 10 true *c 6.448,2.396 6.646,2.563 0.198,0.167 10 true *a 4.688,0.823 4.865,0.99 0.177,0.167 10 true *d 0.323,0.094 0.521,0.365 0.198,0.271 18 false i 0.344,2.042 0.615,2.333 0.271,0.292 18 false iv 1.354,4.427 1.563,4.677 0.208,0.25 18 true iii 3.927,3.031 4.198,3.323 0.271,0.292 18 false v 3.958,0.021 4.229,0.292 0.271,0.271 18 false ii 5.927,0.656 6.104,0.823 0.177,0.167 10 true *h
*a Insertion Point *b SST (Plate)
*c SST (Claw) *d SST (Bolt)
*e SST (Handle) *f Triangle Mark (Fuel Pump Gauge Retainer)
*g Triangle Mark (Fuel Tank Assembly) *h Extension Bar
V100135

Tighten
V100136

Front Side of Vehicle


i.

While pressing down on the fuel suction tube with pump and gauge assembly, temporarily install the fuel pump gauge retainer.


ii.

Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

SST
09808-01071  
09808-14031  (09808-01030, 09808-01090)

HINT:

Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.



iii.

While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).


iv.

Install SST (handle) to SST (plate).

SST
09808-01071  
09808-14031  (09808-01010)


v.

Using SST, rotate the fuel pump gauge retainer so that the triangle mark on the fuel pump gauge retainer is aligned with the triangle mark on the fuel tank assembly to install the fuel suction tube with pump and gauge assembly to the fuel tank assembly.

NOTICE:
·

Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.

·

Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.

·

Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.

·

Do not spin SST too fast or use an impact wrench as this may result in damage to components.

·

If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.

·

Make sure that the fuel suction tube set gasket does not come off.





Hide 77209F 3.CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

a.
A545580C01
3.917,2.083 7,3.5 3.083,1.417 5.417,2.083 5.417,3.5 false 4.667,1.25 5.417,1.25 false 4.354,2.49 4.688,2.49 false 5.917,2.531 6.25,2.531 false 4.521,3.01 4.854,3.01 false 6.094,3.01 6.427,3.01 false 5.865,1.479 6.531,1.479 true 5.875,1.354 6.208,1.354 6.208,1.354 6.208,1.479 true 4.906,1.708 5.24,1.365 false 0.698,1.969 1.031,1.625 true 1.271,1.24 1.469,1.375 true 4.813,1.729 5.125,1.885 0.313,0.156 10 false *1 4.375,1.177 4.688,1.333 0.313,0.156 10 false *2 1.104,1.125 1.323,1.302 0.219,0.177 10 true *3 6.573,1.385 6.885,1.542 0.313,0.156 10 false *a 3.969,2.125 4.281,2.281 0.313,0.156 10 false *b 5.5,2.135 5.813,2.292 0.313,0.156 10 false *c 4.344,2.917 4.656,3.073 0.313,0.156 10 false *d 0.594,1.99 0.813,2.219 0.219,0.229 10 true *2 4.177,2.406 4.49,2.563 0.313,0.156 10 false *2 5.719,2.438 6.031,2.594 0.313,0.156 10 false *2 5.938,2.927 6.25,3.083 0.313,0.156 10 false *d 0.49,0.688 0.729,1.042 0.24,0.354 18 false i
*1 Fuel Suction Plate Sub-assembly *2 Tube Joint Clip
*3 Fuel Tank Main Tube Sub-assembly - -
*a O-ring *b Correct
*c Incorrect *d Collar
V100135

Insert
V100136

Insert


i.

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

NOTICE:
·

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.

·

After installing the tube joint clip, check that the fuel tank main tube sub-assembly is securely connected by pulling on it.





Hide 77289C 4.INSTALL NO. 4 FUEL TUBE CLAMP

Hide 82412 5.INSTALL FUEL GAUGE WIRE

Hide 77404A 6.CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY

a.
A545577N01
1.479,0.146 1.76,0.5 0.281,0.354 18 false i

i.

Connect the fuel tank vent hose sub-assembly to the fuel suction tube with pump and gauge assembly.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (FUEL)>FUEL SYSTEM>PRECAUTION



Hide 77285J 7.INSTALL NO. 1 FUEL TUBE CLAMP

Hide 89461 8.INSTALL FUEL TANK PRESSURE SENSOR (VAPOR PRESSURE SENSOR)

Z101186

Click here(Click here)

Hide 58325M 9.INSTALL REAR FLOOR SERVICE HOLE COVER

a.
A545575N01
0.385,0.063 0.667,0.417 0.281,0.354 18 false i 3.698,0.052 4.094,0.333 0.396,0.281 18 true i, ii 0.188,2.063 0.469,2.417 0.281,0.354 18 false iii 3.719,2 4,2.354 0.281,0.354 18 false iv

i.

Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.


ii.

Clean the installation surfaces of the rear floor service hole cover and vehicle body.


iii.

Connect the fuel pump connector.


iv.

Install the rear floor service hole cover with new butyl tape.

NOTICE:

Securely install the rear floor service hole cover.




Hide 13. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART


Hide 14.PERFORM INITIALIZATION

a.

Perform "Inspection After Repair" after replacing the fuel pump.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION