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Reassembly [09/2014 - ]: Procedure

  1. INSTALL FUEL MAIN VALVE ASSEMBLY (for Brush Type Motor) 
    1. Apply a light coat of gasoline to 2 new O-rings and install them to the fuel main valve assembly.
    2. Install the fuel main valve assembly to the fuel filter.
      NOTE:
      • The fuel main valve assembly has an identification mark (part number). Be sure to install the correct part to the correct location or engine stall may occur.
      • Make sure that the O-rings are not cut or pinched during installation.
      GTY1084314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Identification Mark (Part Number)

      HINT: 

      Fuel Main Valve Assembly 23070-*****
    3. Engage the 2 claws to install the No. 2 fuel suction support to the fuel filter.
      NOTE:

      Securely engage the claws.

  2. INSTALL FUEL PUMP WITH FILTER ASSEMBLY (for Brush Type Motor) 

    HINT: 

    Perform "Inspection After Repair" after replacing the fuel pump with filter assembly.

    Refer to INITIALIZATION [09/2014 - ]

    1. Install the fuel pump spacer to the fuel pump with filter assembly as shown in the illustration.
      GTY1084447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *2 Fuel Pump Spacer
      *a Notch of the fuel pump spacer
      NOTE:

      Install so that the notch of the fuel pump spacer is on the pump side.

    2. Apply a light coat of gasoline to a new O-ring. Then install the O-ring to the fuel pump with filter assembly.
    3. Engage the 3 claws to install the fuel pump with filter assembly to the fuel filter.
      NOTE:
      • Make sure that the O-ring is not cut or pinched during installation.
      • Engage the claws securely.
      • Do not remove the suction filter.
  3. INSTALL NO. 1 FUEL SUCTION SUPPORT (for Brush Type Motor) 
    1. Engage the 2 claws to install the No. 1 fuel suction support to the fuel filter.
  4. INSTALL JET PUMP (for Brush Type Motor) 
    1. Apply a light coat of gasoline to a new O-ring and install the O-ring to the jet pump.
    2. Install the jet pump to the No. 1 fuel sub-tank as shown in the illustration.
      GTY507373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *a Notch
      NOTE:

      Make sure that the O-ring is not cut or pinched during installation.

    3. Engage the claw and install the fuel tube to the No. 1 fuel sub-tank.
      NOTE:

      Securely engage the claw.

  5. INSTALL FUEL FILTER (for Brush Type Motor) 
    1. Engage the 2 claws to install the fuel filter and fuel pump with filter assembly to the No. 1 fuel sub-tank.
      NOTE:
      • Do not apply excessive force to the tube or No. 1 fuel suction support.
      • Securely engage the claws.
      GTY498946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tube
  6. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY (for Brush Type Motor) 
    1. Install the spring to the fuel suction plate shaft.
    2. Install the fuel suction plate sub-assembly to the No. 1 fuel sub-tank.
    3. Install a new E-ring to the fuel suction plate shaft.
    4. Connect the fuel pump harness connector.
      NOTE:

      Make sure that the fuel pump harness connector is engaged securely.

    5. Engage the clamp to connect the fuel pump harness to the fuel suction plate sub-assembly as shown in the illustration.
      NOTE:
      • Engage the connector (A) first and then (B) when connecting the fuel pump harness to the clamp.
      • Do not twist or excessively pull the fuel pump harness.
      GTY495357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL MAIN VALVE ASSEMBLY (for Brushless Type Motor) 
    1. Apply a light coat of gasoline to 2 new O-rings and install them to the fuel main valve assembly.
    2. Install the fuel main valve assembly to the fuel filter.
      NOTE:
      • The fuel main valve assembly has an identification mark (part number). Be sure to install the correct part to the correct location or engine stall may occur.
      • Make sure that the O-rings are not cut or pinched during installation.
      GTY1138067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Identification Mark (Part Number)

      HINT: 

      Fuel Main Valve Assembly 23070-*****
    3. Install the clip to the fuel filter.
  8. INSTALL FUEL PUMP (for Brushless Type Motor) 

    HINT: 

    Perform "Inspection After Repair" after replacing the fuel pump.

    Refer to INITIALIZATION [09/2014 - ]

    1. Apply a light coat of gasoline to a new O-ring. Then install the O-ring and fuel pump spacer to the fuel pump.
      GTY652038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *2 Fuel Pump Spacer
    2. Connect the fuel pump harness connector to install the fuel pump harness to the fuel pump.
    3. Install the fuel pump to the fuel filter.
      NOTE:

      Make sure that the O-ring is not cut or pinched during the installation.

  9. INSTALL FUEL PUMP FILTER (for Brushless Type Motor) 
    1. Engage the 3 claws and install the fuel pump filter to the fuel filter.
      NOTE:
      • Do not damage the fuel filter.
      • Securely engage the claws.
    2. Engage the claw to connect the fuel pump harness to the fuel pump filter.
      NOTE:
      • Securely engage the claw.
      • Make sure that the ground terminal of the fuel pump harness is securely connected to the fuel pump body.
      GTY638998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the connection state of the fuel pump harness.
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Fuel pump body - Ground terminal of the fuel pump harness Always Below 1 Ω

        If the result is not as specified, reconnect the fuel pump harness to the fuel pump filter so that the ground terminal of the fuel pump harness is securely connected to the fuel pump body.

  10. INSTALL NO. 1 FUEL SUCTION SUPPORT (for Brushless Type Motor) 
    1. Engage the 2 claws to install the No. 1 fuel suction support to the fuel filter.
      GTY683018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY (for Brushless Type Motor) 
    1. Apply a light coat of gasoline to a new O-ring and install the O-ring to the jet pump.
      GTY830282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Jet Pump
      *2 O-Ring
    2. Install the spring to the fuel suction plate shaft and then install the fuel suction plate sub-assembly to the No. 1 fuel sub-tank.
    3. Engage the 2 claws to install the fuel filter to the No. 1 fuel sub-tank.
      NOTE:
      • Do not apply excessive force to the tube or No. 1 fuel suction support.
      • Securely engage the claws.
    4. Install the jet pump to the No. 1 fuel sub-tank as shown in the illustration.
      GTY460566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *a Notch
      NOTE:

      Make sure that the O-ring is not cut or pinched during installation.

    5. Engage the 2 claws and connect the jet pump nozzle to the No. 1 fuel sub-tank.
      NOTE:

      Securely engage the claws.

    6. Install a new E-ring to the fuel suction plate shaft.
    7. Engage the clamp to connect the fuel pump harness to the fuel suction plate sub-assembly.
    8. Connect the 2 fuel pump harness connectors.
      NOTE:

      Make sure that the fuel pump harness connector is connected securely.

  12. INSTALL FUEL SENDER GAUGE ASSEMBLY 

    See step  4

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