Denso first time fit - User Manual

Fuel Injection In-Tank Fuel Pump Replacement
Instructions
Prior to the installation of this DENSO First Time Fit
®
fuel pump kit, you must read these
instructions completely.
Definition of Terms
WARNING: Describes precautions that should be observed in order to prevent injury or
death to the user during installation.
CAUTION: Describes precautions that should be observed in order to prevent damage
to the vehicle or its components, which may occur during installation if
sufficient care is not taken.
NOTE: Provides additional information that facilitates installation work.
WARRANTY
NOTE: Information relating to maintaining the DENSO First Time Fit fuel pump
warranty.
General Service Information and Requirements
WARNING: Only trained personnel who have a thorough knowledge of automotive fuel
systems, the proper tools and an appropriate work space should perform repairs to a vehicle’s
fuel system.
WARRANTY NOTE: Read the warranty information found in the DENSO First Time Fit fuel
pump application catalog completely.
WARRANTY NOTE: It is necessary to install a new fuel pump filter to maintain the DENSO
First Time Fit warranty on the replacement fuel pump. In addition, DENSO recommends
replacement of all other fuel filters in the vehicle’s fuel system. Follow the vehicle manufacturer’s
recommended procedures and all vehicle manufacturer’s safety precautions to replace these
fuel filters.
LA990009-2355.1

Summary

Definition of Terms

General Service Information and Requirements

Safety Precautions

Kit Contents

Fuel Pump Replacement Instructions

I. PREPARATIONS

Steps to prepare the vehicle for pump replacement, including relieving fuel pressure and disconnecting the battery.

II. FUEL TANK REMOVAL

Procedures for removing the fuel tank from the vehicle.

III. REMOVE THE TANK UNIT FROM THE FUEL TANK

Steps to remove the fuel pump assembly (tank unit) from the fuel tank.

IV. REMOVE AND REPLACE FUEL PUMP

A) Disassembly Procedure

Detailed steps for disassembling the old fuel pump from the tank unit.

B) Reassembly Procedure

Detailed steps for assembling the new fuel pump into the tank unit.

V. INSTALLATION OF TANK UNIT INTO FUEL TANK

A) Install the new tank seal onto the fuel tank in its proper location.

Install the new seal onto the fuel tank.

B) Be sure the fuel tank is clean inside and carefully install the tank unit assembly into the fuel tank.

Ensure the fuel tank is clean before installing the tank unit assembly.

C) Reinstall the retaining clamp and tighten to manufacturers recommended specifications.

Reinstall and tighten the retaining clamp per manufacturer's specifications.

VI. INSTALL FUEL TANK INTO VEHICLE

A) Lift the fuel tank into position in the vehicle leaving enough room to access the top of the tank.

Position the fuel tank in the vehicle with access to the top.

B) Install the fuel tank retaining straps and tighten the retaining bolts.

Install and tighten fuel tank retaining straps.

C) Reinstall the filler neck and vent hoses.

Reinstall the filler neck and vent hoses.

D) Reinstall any skid plates and shields that may have been removed.

Reinstall any removed skid plates and shields.

VII. WRAP UP

A) Using only equipment designed for use with gasoline, refuel the fuel tank with gasoline.

Refuel the fuel tank with gasoline using appropriate equipment.

B) Inspect the fuel system for leaks and correct them, as necessary.

Inspect the fuel system for leaks and make corrections.

C) With the ignition switch off, reconnect the ground (-) cable to the battery.

Reconnect the battery ground cable with the ignition off.

D) Reinstall the fuel pump relay in the power distribution center.

Reinstall the fuel pump relay in the power distribution center.

E) Start the engine and inspect the fuel lines and connections for leaks.

Start the engine and check fuel lines for leaks.

F) Clear any trouble codes in the electronic control system that may exist as a result of the fuel pump replacement procedure.

Clear diagnostic trouble codes related to the replacement procedure.

Troubleshooting

Denso first time fit Specifications

General

Brand	Denso
Model	first time fit
Category	Water Pump
Language	English