Fuel Pump: Installation

WARNING: This page is about a different variant/trim than selected.

INSTALL FUEL SUCTION TUBE ASSEMBLY (for 4WD)
1. Install a new gasket to the fuel suction tube assembly.
  
  Fig 1: Locating Fuel Suction Tube Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the fuel hose with the clip.
3. Set the fuel suction tube assembly to the fuel tank assembly.
NOTE:
- Make sure that the fuel sender gauge arm does not bend.
- Do not damage the No. 2 fuel hose.
Fig 2: Locating Fuel Suction Tube Assembly (4WD)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION TUBE ASSEMBLY (for 2WD)
1. Install a new gasket onto the fuel tank.
2. Set the fuel suction tube to the fuel tank.
  NOTE: Make sure that the fuel sender gauge arm does not bend.
Fig 3: Locating Fuel Tank Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP GAUGE RETAINER (for 4WD)
1. While holding the fuel suction tube by hand, install the fuel pump gauge retainer to the fuel tank with the 8 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
Fig 4: Locating Fuel Tank With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP GAUGE RETAINER (for 2WD)
1. Align the protrusion of the fuel suction tube with the notch of the fuel tank.
  
  Fig 5: Aligning Protrusion Of Fuel Suction Tube With Notch Of Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While holding the fuel suction tube by hand, align the marks of a new fuel pump gauge retainer and fuel tank as shown in the illustration, then install the fuel pump gauge retainer.
  
  Fig 6: Aligning Marks Of Fuel Pump Gauge Retainer And Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and your hand, tighten the fuel pump gauge retainer 2 revolutions 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 7: Inserting Notch Of SST Into Rib Of Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK VENT HOSE (for 2WD)
1. 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 connecting surfaces 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 on the quick connector.
  Fig 8: Pushing Fuel Tank Vent Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Connect the fuel tank main tube.
  
  Fig 9: Connecting Fuel Tank Main Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 connecting surfaces 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.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSPECT FOR FUEL LEAK (See ON-VEHICLE INSPECTION )
INSTALL REAR FLOOR SERVICE HOLE COVER (for 4WD)
1. Connect the fuel pump connector.
2. Install the rear floor service hole cover.
Fig 10: Locating Rear Floor Service Hole Cover (4WD)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR SERVICE HOLE COVER (for 2WD)
1. Connect the fuel pump connector.
2. Install the rear floor service hole cover.
INSTALL REAR SEAT CUSHION ASSEMBLY (See INSTALLATION )

Fig 11: Locating Rear Floor Service Hole Cover (2WD)