Fuel Pump: Installation: Installation

1. Install a new fuel suction tube set gasket onto the fuel tank as shown in the illustration.
   Fig 1: Fuel Suction Tube Set Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Fuel Suction Tube Set Gasket

2. Set the fuel suction tube with pump and gauge assembly to the fuel tank.
   Fig 2: Protrusion & Notch

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   TEXT IN ILLUSTRATION
   
   

   *a	Protrusion
   *b	Notch

   NOTE:

   Make sure that the fuel sender gauge arm does not bend.

3. Align the protrusions of the fuel suction tube with pump and gauge assembly with the notches of the fuel tank.

1. While holding the fuel suction tube assembly with pump and gauge by hand to prevent it from tilting, align the mark on a new fuel pump gauge retainer with the start mark on the fuel tank and tighten the fuel pump gauge retainer 180° by hand.
   Fig 3: Align The Start Mark & Mark

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a	Start Mark
   *b	Mark
   *c	Front

   HINT: 

   • Check that there is no damage, dents, foreign matter or other defects on the threads of the fuel tank.
2. Temporarily install the SST plate and claws to the fuel pump gauge retainer.
   Fig 4: Plate And Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	SST (Plate)
   *2	SST (Claw)
   *3	Rib

   • SST: 09808-14030 
     1. 09808-01030
     2. 09808-01040
     3. 09808-01050

   HINT: 

   Engage the SST claws securely with the fuel pump gauge retainer ribs to secure SST.

3. While pressing the claws of SST to the fuel pump gauge retainer ribs securely, tighten the bolts.

   HINT: 

   Install SST while pressing the SST claws toward the fuel pump gauge retainer (toward the center of SST).

4. Install the SST handle.
5. Tighten the fuel pump gauge retainer approximately 360° so that the mark on the retainer comes within the range shown in the illustration.
   Fig 5: SST Handle & Fuel Pump Gauge Retainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	SST (Handle)
   *2	SST (Plate)
   *3	SST (Claw)
   *a	Mark
   *b	Front

   • SST: 09808-14030 
     1. 09808-01010
     2. 09808-01020
     3. 09808-01030
     4. 09808-01040
     5. 09808-01050
   NOTE:

   • Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
   • Do not press down on SST excessively as this may make the retainer hard to rotate, and may damage components.
   • Make sure to rotate the SST handle horizontally. If the SST handle is rotated at an angle, SST may come off.
   • Do not spin SST too fast or use an impact wrench as this may result in damage to components.
   • If SST comes off of the retainer, loosen the SST bolts and reinstall SST.

   HINT: 

   • Lightly press down on SST to prevent it from separating from the retainer. While pressing SST, rotate the handle slowly to tighten the retainer.
   • The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

1. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
   Fig 6: Fuel Tube Joint & Tube Joint Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Tube Joint Clip
   *2	Fuel Tube Joint
   *3	O-ring
   *4	Collar
   *a	CORRECT
   *b	INCORRECT

   NOTE:

   • Check that there is no damage or foreign matter around the connecting parts 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 tube joint cannot be pulled out.
2. Connect the fuel pump connector.

1. Push in the fuel tank vent hose connector to the fuel suction tube with pump and gauge assembly and push the retainer so that the claws engage.
   Fig 7: Fuel Tank Vent Hose Connector & Fuel Suction Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Retainer
   	Push

   NOTE:

   • Check that there is no damage or foreign matter around the connecting parts of the fuel tank vent hose connector and fuel suction tube assembly 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 fuel tank vent hose connector.

1. Install the rear floor service hole cover with new butyl tape.
   Fig 8: Rear Floor Service Hole Cover

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Refer to INSTALLATION