Fuel Pump: Reassembly

INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
1. Apply a light coat of gasoline or spindle oil to the 2 new O-rings, and install it to the fuel pressure regulator.
2. Apply a light coat of gasoline or spindle oil to the 2 O-rings again, and install the fuel pressure regulator to the No. 1 fuel tube joint.
3. Install the clip.
  
  Fig 1: Applying Light Coat Of Gasoline Or Spindle Oil To O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP HARNESS
INSTALL NO. 1 FUEL TUBE JOINT
1. Apply a light coat of gasoline or spindle oil to a new O- ring, and install it to the No. 1 fuel tube joint.
2. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the No. 1 fuel tube joint to the fuel suction plate.
3. Connect the connector.
  
  Fig 2: Installing No. 1 Fuel Tube Joint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL FILTER ASSEMBLY
1. Install the fuel filter with a new clip.
INSTALL FUEL PUMP
1. Install the fuel pump spacer to the fuel pump.
2. Apply a light coat of gasoline or spindle oil to a new O- ring, and install it to the fuel pump.
3. Apply a light coat of gasoline or spindle oil to the O- ring again, and install the fuel pump to the fuel suction plate.
4. Connect the fuel pump connector.
  
  Fig 3: Installing Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
1. Apply a light coat of gasoline or spindle oil to a new O- ring, and install it to the No. 1 fuel tube joint.
2. Apply a light coat of gasoline or spindle oil to the O- ring again, and install the fuel suction plate to the No. 1 fuel suction support.
Fig 4: Installing Fuel Suction Plate Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SENDER GAGE ASSEMBLY
INSTALL VAPOR PRESSURE SENSOR
1. Install the vapor pressure sensor with the tube joint clip.
  NOTE:
  - Check that there is no scratch or foreign objects on the connecting parts.
  - Check that the fuel tube joint connector is fully inserted.
  - Check that the fuel tube joint clip is on the collar of the fuel tube joint.
  - After installing the tube joint clip, check if the fuel tube joint connector is securely connected by pulling it.
  Fig 5: Installing Vapor Pressure Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAGE
NOTE: Prior to assembly, all the new components must be stabilized at room temperature for minimum 12 hours.
1. Ensure gasket groove is clean and free of foreign particles.
2. Install a new gasket to the fuel tank.
3. Make sure that the gasket sits in the groove.
4. Align the arrow mark of the fuel suction tube w/ pump and gage tube and the tank suction support.
  
  Fig 6: Aligning Arrow Mark Of Fuel Suction Tube W/Pump & Gage Tube And Tank Suction Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not bend the arm of the fuel sender gage.
5. Align marks on a new fuel pump gauge retainer and the fuel tank.
  
  Fig 7: Aligning Marks On Fuel Pump Gauge Retainer And Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Position the fuel pump gauge retainer on top of the fuel suction w/ pump and gage flange while pushing down the flange on center.
7. While holding the fuel suction tube w/ pump and gage, tighten the pump gauge retainer one complete turn by hand.
  NOTE:
  - Make sure the fuel suction tube w/ pump and gage anti-rotation tab is in the groove during above operation.
  - "S" arrow on the fuel tank indicates 0 degrees position.
8. Ensure that no cross threading occurred during installation by checking the gap between the fuel pump gauge retainer and the fuel tank. Confirm that the gap is even. If cross threading occurred, remove the fuel pump gauge retainer and repeat step ( g).
9. Using SST, tighten the fuel pump gauge retainer to the specified torque.
  SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
  
  Torque: 80 to 90 N*m (816 to 918 kgf*cm, 59 to 67 ft.*lbf)
  
  Fig 8: Tightening Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - No ratcheting effect allowed when tightening the fuel pump gauge retainer.
  - No grease or lubrication allowed on parts during installation.
  HINT:
  
  A rib on the fuel pump gauge retainer can be fitted into a tip of the SST.
10. Install the fuel pump gauge retainer by one and half turn so that the triangle mark on the fuel pump gauge retainer is between 510° and 570° from the start position.
11. If the triangle mark is not reached 510°, confirm that no cross threading occurred by measuring the gap between the fuel pump gauge retainer and the fuel tank.
  If cross threading occurred, replace the fuel pump gauge retainer, the gasket and the tank suction tube support.
12. Replace the tank suction tube support.
  1. Remove the tank suction tube support from the fuel tank.
    
    Fig 9: Removing Tank Suction Tube Support From Fuel Tank
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Install the tank suction tube support to the fuel tank as shown in Fig 10 .
    
    Fig 10: Installing Tank Suction Tube Support To Fuel Tank
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Put a mark on the fuel pump gauge retainer and the fuel tank with paint. This will be the evidence that the fuel pump gauge retainer had been removed.
  
  Fig 11: Putting Mark On Fuel Pump Gauge Retainer And Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Install in the fuel return tube with the tube joint clip.
  NOTE:
  - Check that there is no scratch or foreign objects on the connecting part.
  - Check that the fuel tube joint is inserted securely.
  - 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 joint has not been pulled off.
  Fig 12: Installing Fuel Tank Main Tube Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK TO FILLER PIPE HOSE (See REASSEMBLY )