Fuel Pump: Installation

INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
1. Apply a light coat of gasoline to a new No. 1 fuel suction tube set gasket, and install it to the fuel tank.
  
  Fig 1: Locating Fuel Sender Gauge Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Push in the tube connector to the pipe until the tube connector makes a "click" sound, and set the fuel suction tube assembly with pump and gauge.
  NOTE:
  - Check that there is no damage or foreign objects on the connected part of the fuel pipe.
  - After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
  - Be careful not to bend the arm of the fuel sender gauge.
    
    Fig 2: [Pushing Tube Connector]
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the protrusion of the fuel suction tube and the cutout of the fuel tank.
  
  Fig 3: Aligning Protrusion Of Fuel Suction Tube And Cutout Of Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. While holding the fuel suction tube by hand, align the start marks of a new fuel pump gauge retainer and the fuel tank. Install the fuel pump retainer to the fuel tank.
  
  Fig 4: Aligning Start Marks Of Fuel Pump Gauge Retainer And Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
  SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
  
  NOTE: Do not use any other tools such as a screwdriver.
  
  HINT:
  
  Fit the tips of SST on the ribs of the retainer.
  
  Fig 5: Setting SST To Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that the start mark on the retainer is within the indicated range in the illustration.
  
  Fig 6: Tightening Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the fuel pump tube sub-assembly and return tube.
  1. Push the fuel tube joint into the plug of the fuel suction plate, then install the 2 tube joint clips.
8. Connect the fuel suction tube connector.
  NOTE:
  - Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work.
  - Check that the fuel tube joint is securely inserted.
  - 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 tube cannot be pulled out.
    
    Fig 7: Identifying Fuel Tube Joint And Tube Joint Clip
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Connect the fuel pump connector.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
INSPECT FOR FUEL LEAK (See ON-VEHICLE INSPECTION )

Fig 8: Locating Fuel Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
1. Install the rear floor No. 2 service hole cover with new butyl tape.
  
  Fig 9: Locating Rear Floor No. 2 Service Hole Cover With Butyl Tape
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ROOM NO. 3 PARTITION PAD
1. Install the room No. 3 partition pad with the clip.
INSTALL REAR SEAT CUSHION ASSEMBLY (See INSTALLATION )

Fig 10: Identifying Clip And Room Partition Pad
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002