Fuel Pump Installation

Apply a light coat of diesel fuel to a new O-ring, and install it to the fuel pressure regulator.

Push in the fuel pressure regulator to the fuel filter.

Install the fuel pump cushion rubber to the fuel pump.

Install the No. 2 fuel suction support to the fuel pump.

Apply a light coat of diesel fuel to the O-ring of the fuel pump.

Push in the fuel pump to the fuel filter.

Install the No. 2 fuel suction support.

Apply a light coat of diesel fuel to a new O-ring, and install the O-ring to the fuel return jet tube.

Push in the fuel return jet tube to the housing.

Set the jet pump housing to the fuel filter. Then slide the jet pump housing downward to install it.

HINT:

Make sure that the housing is engaged at the 2 positions as shown in the illustration.

Connect the fuel pump harness to the fuel suction plate sub-assembly(^*1).

Install the fuel pump harness(^*2).

Apply a light coat of diesel fuel of a O-ring and fuel hose.

Connect the fuel pump connector.

Align the fuel hose and install the fuel suction plate.

Connect the fuel suction filter.

Slide the fuel sender gauge to engage the claws.

Install a new gasket to the fuel suction tube assembly.

Connect the No. 2 fuel hose with the clip as shown in the illustration.

Set the fuel suction tube to the fuel tank.

NOTICE:

1. Make sure that the fuel sender gauge arm does not bend.
   
2. Do not damage the No. 2 fuel hose.
   

Align the protrusion of the fuel suction tube and the cutout of the fuel tank vent tube set plate.

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}

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.
   

   NOTICE:

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




2. Push the fuel tube joint in the plug of the fuel suction plate, then install the 2 tube joint clips.
   

   NOTICE:

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

Connect the fuel suction tube connector.

PERFORM ACTIVE TEST

1. Connect the intelligent tester to the DLC3.
   

2. Turn the engine switch ON (IG).
   

3. Turn the intelligent tester ON.
   

4. Enter the following menus: Powertrain / ENGINE / Active Test.
   

5. Perform the Active Test.
   
   

   Intelligent Tester Display	Test Details	Control Range	Diagnostic Notes
   Test the Fuel Leak	Pressurize common rail internal fuel pressure, and check for fuel leaks	Stop/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when "Start" is selected Above conditions to be maintained while "Start" is selected

Install the rear No. 2 floor service hole cover with new butyl tape.

Attach the 2 rear hooks of the seat cushion to the seatback.

Attach the 2 front hooks of the seat cushion to the vehicle body.

Confirm that the seat cushion is firmly installed.

NOTICE:

When installing the seat cushion, make sure the seat belt buckle is not under the seat cushion.

Perform initialization procedure (Click here).

HINT:

Some vehicle systems require initialization after reconnecting the negative battery terminal.