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Fuel Pump: Installation

  1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY 
    1. Apply a light coat of gasoline to 2 new O-rings, and install them to the fuel pressure regulator.
      Fig 1: Identifying O-Rings
      G05287021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel pressure regulator to the fuel relief valve.
    3. Install the clip to the relief valve.
    Fig 2: Installing Clip To Relief Valve
    G05287024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL JET PUMP 
    1. Apply a light coat of gasoline to a new O-ring, and install a new O-ring and the jet pump to the fuel relief valve.
    Fig 3: Installing O-Ring And Jet Pump To Fuel Relief Valve
    G05287025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL RELIEF VALVE ASSEMBLY 
    1. Apply a light coat of gasoline to a new O-ring, and install a new O-ring and the fuel relief valve to the fuel filter.
    Fig 4: Installing O-Ring And Fuel Relief Valve To Fuel Filter
    G05287026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FLANGE ASSEMBLY 
    1. Apply a light coat of gasoline to a new O-ring, and install the O-ring to the flange. Then attach the 2 claws to install the flange to the fuel filter.
    Fig 5: Installing O-Ring To Flange
    G05287027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL PUMP ASSEMBLY 
    1. Install the fuel pump spacer to the fuel pump.
    2. Apply a light coat of gasoline to a new seal, and install it to the fuel pump.
    3. Attach the 2 claws to install the fuel pump to the fuel filter.
      Fig 6: Installing Fuel Pump Spacer To Fuel Pump
      G05287028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 2 connectors and terminal, and install the fuel pump wire.
    Fig 7: Locating Fuel Pump Connectors
    G05287014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 FUEL SUB-TANK 
    1. Apply gasoline to a new O-ring and install it to the jet pump.
    2. Install the jet pump while aligning it to the installation position of the sub-tank.
      Fig 8: Aligning Installation Position Of Sub-Tank
      G05287030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the jet pump nozzle to the sub-tank.
    4. Attach the 3 claws to the claw holes and install the sub-tank.
      Fig 9: Identifying Claws
      G05287031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install a new E-ring.
    Fig 10: Identifying E-Ring
    G05287010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL SENDER GAUGE ASSEMBLY 
    1. Set the fuel sender gauge to the sub-tank. Then slide the sender gauge downward to install it.
    2. Connect the fuel sender gauge connector.
  8. INSTALL FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY 
    1. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
    2. Connect the fuel return vent tube and set the fuel suction with pump and gauge assembly.
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge.
      • When connecting the fuel return vent, tube connector do not forcibly pull the tube.
    3. Align the protrusion of the flange assembly and the cutout of the fuel tank.
      Fig 11: Locating Fuel Sender Gauge Assembly
      G05287033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 12: Aligning Protrusion Of Flange Assembly And Cutout Of Fuel Tank
      G05287034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. While holding the flange assembly by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Then install the fuel pump gauge retainer to the fuel tank.
      Fig 13: Aligning Starting Marks Of Fuel Pump Gauge Retainer And Fuel Tank
      G05287035Courtesy 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) 

      HINT:

      Fit the tips of SST on the ribs of the retainer.

      NOTE: Use SST. Do not use any other tools such as a screwdriver.
      Fig 14: Identifying SST On Ribs Of Retainer
      G05287006Courtesy 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 starting mark on the retainer is within the indicated range in the illustration.
      Fig 15: Tightening Fuel Pump Gauge Retainer
      G05287037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the fuel pump tube.
      Fig 16: Connecting Fuel Pump Tube
      G05287038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Push the fuel tube joint into the plug of the fuel suction plate, then install the tube joint clip.
        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.
  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  10. INSPECT FOR FUEL LEAK (See  ON-VEHICLE INSPECTION  ) 
  11. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Connect the fuel pump connector.
    2. Install the service hole cover with new butyl tape.
    Fig 17: Locating Service Hole Cover Connector
    G05287004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL ROOM NO. 3 PARTITION PAD 
    1. Install the partition pad with the clip.
      Fig 18: Identifying Partition Pad With Clip
      G05287003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR SEAT CUSHION ASSEMBLY (See  INSTALLATION  ) 
  14. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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