Fuel Pump: Installation: Installation

INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
1. Apply a light coat of gasoline to 2 new O-rings, and install them to the fuel pressure regulator.
  
  Fig 1: Identifying Fuel Pressure Regulator O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the fuel pressure regulator to the fuel relief valve.
  
  Fig 2: Installing Clip To Relief Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL JET PUMP
1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and jet pump to the fuel relief valve assembly.
  
  Fig 3: Installing O-Ring & Jet Pump To Fuel Relief Valve Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL RELIEF VALVE ASSEMBLY
1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and fuel relief valve assembly to the fuel filter.
  
  Fig 4: Identifying Fuel Relief Valve O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FLANGE ASSEMBLY
1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and flange assembly to the fuel filter.
  
  Fig 5: Identifying Flange Assembly O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP
1. Install the fuel pump spacer to the fuel pump.
  
  Fig 6: Installing Fuel Pump To Fuel Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of gasoline to a new seal, and install it to the fuel pump.
3. Install the fuel pump to the fuel filter.
4. Connect the 2 connectors and terminal.
  
  Fig 7: Locating Connectors And Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FUEL SUB-TANK
1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and No. 1 fuel sub-tank to the fuel filter with flange assembly.
  
  Fig 8: Identifying No. 1 Fuel Sub-Tank O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the jet pump nozzle to the No. 1 fuel sub-tank.
  
  Fig 9: Connecting Jet Pump Nozzle To No 1 Fuel Subtank. O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new E-ring.
  
  Fig 10: Identifying E-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SENDER GAUGE ASSEMBLY
1. Set the fuel sender gauge to the No. 1 fuel sub-tank. Then slide the sender gauge downward to install it.
  
  Fig 11: Installing Fuel Sender Gauge Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the fuel sender gauge connector.
INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
1. Install a new gasket onto the fuel tank.
2. Connect the fuel hose with the clip.
  
  Fig 12: Identifying Fuel Suction Tube & Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set the fuel suction tube to the fuel tank.
  NOTE:
  - Make sure that the fuel sender gauge arm does not bend.
  - Do not damage the No. 2 fuel hose.
4. Align the protrusion of the fuel suction tube and the cutout of the fuel tank vent tube set plate.
  
  Fig 13: Aligning Protrusion Of Fuel Suction Tube And Cutout Of Fuel Tank Vent Tube Set Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. 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)
6. 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.
    
    Fig 14: Installing Fuel Tube Joint Clips
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    Check that there are no scratches or foreign objects on the connecting parts.
    
    Check that the fuel tube joint is inserted securely.
    
    Check that the tube joint clips are on the collars of the fuel tube joints.
    
    After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
    
    Be careful not to damage any clips. If a clip is damaged, replace it.
7. Connect the fuel suction tube connector.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL . Refer to INSTALLATION - Step 92
INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1
INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER
1. Install the No. 2 rear floor service hole cover with new butyl tape.
  
  Fig 15: Identifying Fuel Suction Tube Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 4