Fuel Pump: Installation

INSTALL FUEL PUMP
1. Apply a light coat of gasoline or spindle oil to a new O-ring, then install it into the fuel pump.
  
  Fig 1: Locating O-Ring On Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of gasoline or spindle oil to the O-ring of the fuel pump again, then push the fuel pump into the fuel filter.
  NOTE: Make sure that the O-ring is not cracked or jammed when installing.
  
  Fig 2: Pushing Fuel Pump Into Fuel Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
1. Apply a light coat of gasoline or spindle oil to 2 new O-rings, then install them onto the fuel pressure regulator.
  
  Fig 3: Identifying O-Rings On Fuel Pressure Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of gasoline or spindle oil to the O-rings of the fuel pressure regulator again, then push the fuel pressure regulator into the fuel filter.
  NOTE: Make sure that the O-ring is not cracked or jammed when installing.
  
  Fig 4: Pushing Fuel Pressure Regulator Into Fuel Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP FILTER
1. Engage the 5 claws, then install the fuel pump filter onto the fuel filter.
  
  Fig 5: Installing Fuel Pump Filter Onto Fuel Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FUEL SUCTION SUPPORT
1. Engage the claws, then install the No. 1 fuel suction support onto fuel suction plate.
  
  Fig 6: Installing No. 1 Fuel Suction Support Onto Fuel Suction Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP HARNESS
1. Connect the 2 fuel pump harness connectors.
  
  Fig 7: Locating Fuel Pump Harness Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
1. Engage the 2 claws, then install the fuel suction plate and spring into the fuel suction case.
  
  Fig 8: Identifying Claws On Fuel Suction Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the claw, then install the fuel pump filter onto the fuel suction case.
  
  Fig 9: Identifying Claw Position On Fuel Pump Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new E-ring.
  
  Fig 10: Locating E-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SENDER GAUGE ASSEMBLY
1. Slide the fuel sender gauge to fit the claw (A).
2. Connect the fuel sender gauge connector (B).
  
  Fig 11: Installing Fuel Sender Gauge Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
1. Install a new gasket onto the fuel tank.
  
  Fig 12: Locating Fuel Tank Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set the fuel suction tube to the fuel tank.
  NOTE: Make sure that the fuel sender gauge arm does not bend.
3. Align the protrusion of the fuel suction tube with the notch of the fuel tank.
  
  Fig 13: Aligning Protrusion Of Fuel Suction Tube With Notch Of Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. While holding the fuel suction tube by hand, align the marks of a new fuel pump gauge retainer and fuel tank as shown, then install the fuel pump gauge retainer.
  
  Fig 14: Aligning Marks Of Fuel Pump Gauge Retainer And Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST and your hand, tighten the fuel pump gauge retainer 2 revolution so that the mark of the retainer comes within the range shown in the illustration.
  SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
  
  NOTE: Use SST. Do not use any other tools such as a screwdriver.
  
  HINT:
  
  Insert the notch of SST into the rib of the fuel pump gauge retainer.
  
  Fig 15: Tightening Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the fuel tank vent hose.
  1. Align the fuel tank vent connector with the pipe, then push in the fuel tank vent connector until the retainer makes a "click" sound to connect the fuel tank vent hose to the fuel suction plate.
    NOTE:
    Check that there are no scratches or foreign objects around the connected part of the fuel tank vent connector and pipe before performing this work.
    
    After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the quick connector.
    
    Fig 16: Connecting Fuel Tank Vent Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the fuel tank main tube.
  1. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
    NOTE:
    Check that there are no scratches or foreign objects around the connected part of the fuel tube joint and plug before performing this work.
    
    Check that the fuel tube joint is securely inserted to the end.
    
    Check that the tube joint clip is on the collar of the fuel tube joint.
    
    After installing the tube joint clip, check that the fuel tank main tube cannot be pulled out.
    
    Fig 17: Connecting Fuel Tank Main Tube
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
INSPECT FOR FUEL LEAK
NOTE: Check for fuel leaks with the fuel pump connector connected.
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Connect the fuel pump connector (A).
2. Install the rear floor service hole cover with the 4 screws (B).
  
  Fig 18: Installing Rear Floor Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR SEAT CUSHION ASSEMBLY RH
1. Install the rear seat cushion with the 2 bolts.
  Torque: 41 N*m (420 kgf*cm, 30 ft.*lbf)
  
  Fig 19: Locating Rear Seat Cushion Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002