Removal and Installation
REMOVALNOTE: Always use "Torx" socket wrench E10 when removing the rear seat.
1. REMOVE REAR SEAT CUSHION COVER PAD (for Hatchback)
2. REMOVE REAR SEAT CUSHION COVER PAD (for Sedan)
3. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for Hatchback)
4. REMOVE DECK BOARD SUB-ASSEMBLY (for Hatchback)
5. REMOVE DECK FLOOR BOX (for Hatchback)
6. REMOVE REAR SEAT LEG COVER NO. 1 (for Hatchback)
7. REMOVE REAR SEAT LEG COVER NO. 2 (for Hatchback)
8. REMOVE REAR SEAT ASSEMBLY (for Hatchback)
9. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear floor service hole cover.
b. Disconnect the fuel pump connector.
10. DISCHARGE FUEL SYSTEM PRESSURE
a. Discharge the fuel system pressure.
11. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
12. DISCONNECT FUEL TANK MAIN TUBE SUBASSEMBLY
a. Widen the tip of the tube joint clip and pull out the clip in the direction indicated by the arrow.
b. Disconnect the fuel tank main tube.
NOTE:
- Keep the O-ring free of any foreign matter, as it becomes contaminated easily.
- Do not use any tools in this procedure.
- Do not forcefully bend or twist the tube.
- Put the tube in a plastic bag to prevent damage and contamination.
- If the fuel suction plate and tube are stuck together, pinch the tube and turn it carefully to disconnect them.
- Do not damage any clips. If a clip is damaged, replace it.
13. DISCONNECT FUEL TANK VENT HOSE SUBASSEMBLY
a. Disconnect the fuel tank vent hose.
14. REMOVE FUEL PUMP GAUGE RETAINER
a. Using SST, remove the fuel pump gauge retainer.
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
HINT: Align the claws of the fuel pump gauge retainer with the tips of SST.
15. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
a. Remove the fuel suction with pump and gauge tube.
NOTE: Do not bend the arm of the sender gauge.
b. Remove the fuel suction tube gasket from the fuel tank.
INSTALLATION
NOTE: Always use "Torx" socket wrench E10 when installing the rear seat.
1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
a. Install a new fuel suction tube gasket onto the fuel tank.
b. Align the protrusion of the fuel pump with the cutout of the fuel tank and install the fuel suction with pump and gauge tube assembly.
NOTE: The arm of the sender gauge should not be bent.
2. INSTALL FUEL PUMP GAUGE RETAINER
a. Using SST, turn the retainer 540° clockwise from the screw starting point and align the claw of the retainer with the match mark on the fuel tank.
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
NOTE: Replace the fuel pump gauge retainer with a new one if not installed properly. Part No. 77144-52040
HINT:
- Align the claws of the fuel pump gauge retainer with the tips of SST.
- At the point where the retainer is turned 90° from the start of the thread, push the retainer in from the opposite side to the start of the thread. Check that the thread of the retainer is properly engaged with that on the tank.
3. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY
a. Connect the fuel tank vent hose.
4. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Insert the fuel tank main tube.
b. Install the tube joint clip.
NOTE:
- Check that there are no scratches or foreign matter on the connecting parts.
- Check that the fuel tube joint is inserted securely.
- After installing the tube joint clip, check that the fuel tube joint has not been pulled off.
- Do not damage any clips. If a clip is damaged, replace it.
5. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel pump connector.
b. Install the rear service hole cover with new butyl tape.
6. INSTALL REAR SEAT ASSEMBLY (for Hatchback)
7. INSTALL REAR SEAT LEG COVER NO. 2 (for Hatchback)
8. INSTALL REAR SEAT LEG COVER NO. 1 (for Hatchback)
9. INSTALL DECK FLOOR BOX (for Hatchback)
10. INSTALL DECK BOARD SUB-ASSEMBLY (for Hatchback)
11. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Hatchback)
12. INSTALL REAR SEAT CUSHION COVER PAD (for Sedan)
13. INSTALL REAR SEAT CUSHION COVER PAD (for Hatchback)
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf.cm, 48 in. lbs.)
15. CHECK FOR FUEL LEAKAGE