RM38N0EC _51 Engine / Hybrid System _111793 M20C-FKS, M20D-FKS FUEL _0504181 FUEL PUMP A

M20C-FKS, M20D-FKS FUEL  FUEL PUMP  INSTALLATION  


CAUTION / NOTICE / HINT

NOTICE:
A499868C01
1.823,1.885 1.823,1.625 true 1.76,1.896 1.969,2.104 0.208,0.208 10 false *a
*1 Fuel Return Vent Tube Sub-Assembly
V100135

Front of the Vehicle


Make sure to correctly assemble the fuel return vent tube sub-assembly as shown in the illustration. If assembled incorrectly, the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) may catch on the fuel return vent tube sub-assembly resulting in incorrect operation of the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) and an incorrect value being displayed on the fuel gauge.


PROCEDURE

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

a.

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


b.

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

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION

A499842C01
1.385,1.75 1.531,1.948 1.531,1.948 1.531,2.167 true 4.74,1.635 4.854,1.448 4.854,1.448 5.063,1.448 true 4.844,1.792 4.844,2.094 true 1.458,0.802 1.573,0.615 1.573,0.615 1.781,0.615 true 1.427,1.542 1.802,1.542 true 4.688,1.135 4.802,0.948 4.802,0.948 5.01,0.948 true 1.438,2.188 1.833,2.448 0.396,0.26 10 false *1 1.844,1.469 2.104,1.667 0.26,0.198 10 false *2 5.052,0.865 5.406,1.146 0.354,0.281 10 false *3 1.823,0.531 2.104,0.74 0.281,0.208 10 false *3 5.135,1.365 5.406,1.552 0.271,0.188 10 false *2 4.844,2.125 5.219,2.438 0.375,0.313 10 false *1
*1 Fuel Sender Gauge Assembly *2 Fuel Sub-tank Sub-assembly
*3 Fuel Suction Plate Sub-assembly - -


NOTICE:
·

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

·

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.




c.
A499843C01
2.729,0.823 2.854,0.656 2.854,0.656 2.99,0.656 true 3.073,0.552 3.229,0.75 0.156,0.198 10 true a
*a Protrusion
V100135

Notch


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.

Install the fuel pump gauge retainer.

i.

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


ii.
A499840C01
0.719,0.552 0.896,0.552 0.896,0.552 1.281,0.771 true 2.427,0.875 2.635,0.625 2.635,0.625 2.823,0.625 true 1.865,1.615 2.073,1.969 2.073,1.969 2.26,1.969 true 0.698,1.188 1.219,1.188 true 0.708,2.844 0.969,3.125 0.969,3.125 1.469,3.125 true 2.5,1.396 3.021,1.396 true 1.448,3.042 1.667,3.26 0.219,0.219 10 true *a 2.313,1.875 2.51,2.073 0.198,0.198 10 true *b 0.479,1.083 0.667,1.281 0.188,0.198 10 true *c 0.51,0.479 0.688,0.667 0.177,0.188 10 true *d 2.885,0.542 3.083,0.719 0.198,0.177 10 true *d 3.073,1.281 3.26,1.479 0.188,0.198 10 true *c
*a Insertion Point
*b SST (Plate)
*c SST (Claw)
*d SST (Bolt)


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

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

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.
A499844C01
0.927,1.177 1.229,1.177 1.229,1.177 1.333,1.365 true 1.292,0.323 1.417,0.323 1.417,0.323 1.646,0.635 true 1.198,1.885 1.531,1.885 true 2.219,1.542 2.49,1.792 2.49,1.792 2.677,1.792 true 1.448,3.115 1.719,3.115 1.719,3.115 1.958,2.958 true 2.208,2.625 2.604,2.625 true 1.24,3.042 1.417,3.198 0.177,0.156 10 true *a 2.635,2.521 2.854,2.74 0.219,0.219 10 true *b 1.094,0.24 1.281,0.406 0.188,0.167 10 true *c 1,1.813 1.177,2 0.177,0.188 10 true *d 0.771,1.094 0.917,1.333 0.146,0.24 10 false *e 2.76,1.708 2.948,1.927 0.188,0.219 10 true *e
*a Triangle Mark (Fuel Pump Gauge Retainer)
*b Triangle Mark (Fuel Tank Assembly)
*c SST (Handle)
*d SST (Plate)
*e SST (Bolt)


Install SST (handle) to SST (plate).

SST
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.





b.

Engage the claw to install the No. 1 fuel tube clamp.


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

a.

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

A499845C01
5.667,1.417 6.833,2.656 1.167,1.24 4.01,1.417 5.167,2.656 1.156,1.24 2.948,0.979 3.198,0.979 true 5.646,0.333 5.979,0.333 false 5.833,0.646 6.167,0.646 false 4.677,1.031 4.833,1.031 4.833,1.031 4.917,0.771 false 6.24,1.927 6.354,1.594 6.354,1.594 6.51,1.594 true 4.667,1.979 4.49,2.333 4.49,2.333 4.344,2.333 true 5.656,0.865 6.208,0.865 true 5.667,0.75 6.052,0.75 6.052,0.75 6.052,0.865 true 2.677,1.458 3.063,1.458 true 4.458,0.969 4.771,1.135 0.313,0.167 10 false *1 6.25,0.573 6.604,0.844 0.354,0.271 10 false *2 3.104,1.375 3.323,1.563 0.219,0.188 10 true *3 6.073,0.25 6.427,0.469 0.354,0.219 10 false *a 6.25,0.771 6.635,1.094 0.385,0.323 10 false *b 4.073,1.469 4.396,1.698 0.323,0.229 10 false *c 5.771,1.49 6.104,1.698 0.333,0.208 10 false *d 4.146,2.26 4.49,2.531 0.344,0.271 10 false *e 3.229,0.896 3.427,1.094 0.198,0.198 10 true *2 6.594,1.51 6.917,1.813 0.323,0.302 10 false *e
*1 Fuel Suction Plate Sub-assembly *2 Tube Joint Clip
*3 Fuel Tank Main Tube Sub-assembly - -
*a Fuel Tube Joint *b O-ring
*c Correct *d Incorrect
*e Collar - -
V100135

Insert
V100136

Insert


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 58325E 4.INSTALL REAR FLOOR SERVICE HOLE COVER (for LH Side)

a.

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


b.

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


c.

Connect the 2 fuel pump connectors to the fuel suction tube with pump and gauge assembly.


d.
A476884C01
0.583,1.115 0.969,1.115 true 0.406,1.021 0.583,1.188 0.177,0.167 10 true *a
*a Butyl Tape Adhesion Area


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

NOTICE:

Securely install the rear floor service hole cover.



Hide 10. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>WORK PROCEDURE

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