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Fuel Pump: Installation: Installation

NOTE:

Always use "Torx" socket wrench E10 when installing the rear seat.

  1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    Fig 1: Identifying Fuel Suction, Pump And Gauge Tube
    GTY165892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new fuel suction tube gasket onto the fuel tank.
    2. Align the protrusion of the fuel pump with the cutout of the fuel tank and install the fuel suction with pump and gauge tube assembly.
      Fig 2: Aligning Protrusion Of Fuel Pump With Cutout Of Fuel Tank
      GTY225656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      The arm of the sender gauge should not be bent.

  2. INSTALL FUEL PUMP GAUGE RETAINER 
    Fig 3: Identifying Fuel Pump Gauge Retainer
    GTY237349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, turn the retainer 540° clockwise from the screw starting point and align the claw of the retainer with the matchmark on the fuel tank.
      • SST: 09808-14020 
        • 09808-01410
        • 09808-01420
        • 09808-01430
      NOTE:

      Replace the fuel pump gauge retainer with a new one if not installed properly.

      • Part No. 77144-52040

      HINT: 

      • Align the claws of the fuel pump gauge retainer with the tips of SST.
      • At the point where the retainer is turned 90° from the start of the thread, push the retainer in from the opposite side to the start of the thread. Check that the thread of the retainer is properly engaged with that on the tank.
  3. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    Fig 4: Identifying Fuel Tank Vent Hose
    GTY237358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the fuel tank vent hose.
  4. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    Fig 5: Connecting Fuel Tank Main Tube Sub-Assembly
    GTY163145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Insert the fuel tank main tube.
    2. Install the tube joint clip.
      NOTE:
      • Check that there are no scratches or foreign matter on the connecting parts.
      • Check that the fuel tube joint is inserted securely.
      • After installing the tube joint clip, check that the fuel tube joint has not been pulled off.
      • Do not damage any clips. If a clip is damaged, replace it.
  5. INSTALL REAR FLOOR SERVICE HOLE COVER 
    Fig 6: Locating Fuel Pump Assembly Connector
    GTY237203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the fuel pump connector.
    2. Install the rear service hole cover with new butyl tape.
      Fig 7: Locating Rear Service Hole Cover With Butyl Tape
      GTY237202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL REAR SEAT ASSEMBLY (for Hatchback)  . Refer to INSTALLATION - Step 1
  7. INSTALL REAR SEAT LEG COVER NO. 2 (for Hatchback)  . Refer to INSTALLATION - Step 2
  8. INSTALL REAR SEAT LEG COVER NO. 1 (for Hatchback)  . Refer to INSTALLATION - Step 3
  9. INSTALL DECK FLOOR BOX (for Hatchback)  . Refer to INSTALLATION - Step 4
  10. INSTALL DECK BOARD SUB-ASSEMBLY (for Hatchback)  . Refer to INSTALLATION - Step 66
  11. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Hatchback)  . Refer to INSTALLATION - Step 67
  12. INSTALL REAR SEAT CUSHION COVER PAD (for Sedan)  . Refer to INSTALLATION - Step 2
  13. INSTALL REAR SEAT CUSHION COVER PAD (for Hatchback)  . Refer to INSTALLATION - Step 3
  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  15. CHECK FOR FUEL LEAKAGE  . Refer to ON-VEHICLE INSPECTION - Step 1
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