Removal & Installation and Disassembly & Reassembly

NOTE: When disconnecting the battery terminal, initialize the following system after the terminal is reconnected.

SYSTEM SPECIFICATIONS

System	Refer To
Power window control system	INITIALIZATION
Sliding roof system	INITIALIZATION

DISCONNECT BATTERY NEGATIVE TERMINAL
REMOVE RR SEAT CUSHION ASSY (See OVERHAUL )
REMOVE REAR FLOOR SERVICE HOLE COVER
1. Remove the butyl tape, then remove the rear floor service hole cover.
2. Disconnect the fuel pump connector.
3. Discharge the fuel system pressure.
  1. Start the engine.
  2. Turn the ignition switch to OFF after the engine stops.
    
    Fig 1: Disconnecting Fuel Pump Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    DTC P0171 (system to lean) may be present.
  3. Crank the engine again and check that the engine does not start.
  4. Remove the fuel tank cap, then discharge the pressure in the fuel tank completely.
4. Disconnect the wire to wire connector.
REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY
1. Disconnect the fuel tank main tube.
  1. Remove the tube joint clip, then pull the fuel tube joint out of the plug of the fuel suction plate.
  Fig 2: Disconnecting Fuel Tank Main Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove dirt and foreign objects on the fuel tube joint before performing this work.
  - Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube joint has the O-ring that seals the plug.
  - Perform this work by hand. Do not use any tools.
  - Do not forcibly bend, twist or turn the nylon tube.
  - Protect the disconnected part by covering it with a vinyl bag and gum tape after disconnecting the fuel tank main tube.
  Fig 3: Identifying Sectional View Of Fuel Tank Main Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts, then remove the fuel tank protector plate.
  
  Fig 4: Removing Fuel Tank Protector Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 6 bolts, then remove the fuel tank vent tube set plate.
  
  Fig 5: Removing Fuel Tank Vent Tube Set Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the fuel suction with pump and gauge tube from the fuel tank.
  NOTE:
  - Do not damage the fuel pump filter.
  - Make sure that the fuel sender gauge arm does not bend.
  Fig 6: Removing Fuel Suction With Pump And Gauge Tube From Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the gasket from the fuel suction tube with pump and gauge tube.
  
  Fig 7: Removing Gasket From Fuel Suction Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SENDER GAUGE ASSY
1. Separate the 2 claws fittings, then slide the fuel sender gauge to remove it from the fuel filter.
Fig 8: Removing Fuel Sender Gauge Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SUCTION PLATE SUB-ASSY
1. Disconnect the fuel pump harness connector.
2. Using a screwdriver with its tip wrapped in tape, separate the 4 claws fittings. Then remove the fuel suction plate.
NOTE: Do not damage the fuel suction plate or fuel tank fuel filter.

Fig 9: Removing Fuel Suction Plate Sub-Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP HARNESS
1. Remove the 2 pump harness terminals.
2. Disconnect the pump harness connector, then remove the fuel pump harness.
Fig 10: Removing Fuel Pump Harness
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SUCTION SUPPORT NO.2
1. Using a screwdriver with its tip wrapped in tape, separate the 5 claws fittings. Then remove the fuel suction support No. 2.
NOTE: Do not damage the fuel suction support No. 2 or fuel tank fuel filter.

Fig 11: Removing Fuel Suction Support No.2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP CUSHION RUBBER
1. Remove the fuel pump cushion rubber from the fuel pump.
Fig 12: Removing Fuel Pump Cushion Rubber
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP
1. Pull the fuel pump out of the fuel filter.
Fig 13: Removing Fuel Pump
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP FILTER
1. Using a small screwdriver, pry out the clip.
2. Remove the fuel pump filter from the fuel pump.
Fig 14: Removing Fuel Pump Filter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PRESSURE REGULATOR ASSY
1. Pull the fuel pressure regulator out of the fuel tank fuel filter.
  
  Fig 15: Removing Fuel Pressure Regulator Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the fuel pressure regulator.
  
  Fig 16: Removing O-Ring From Fuel Pressure Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PRESSURE REGULATOR ASSY
1. Apply a light coat of gasoline or spindle oil to a new O-ring, then install it onto the fuel pressure regulator.
  
  Fig 17: Installing Fuel Pressure Regulator Assy (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of gasoline or spindle oil to the O-ring again, then push the fuel pressure regulator into the fuel tank fuel filter.
  NOTE: Make sure that the O-ring is not cracked or jammed when installing.
  
  Fig 18: Installing Fuel Pressure Regulator Assy (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP FILTER
1. Install the fuel pump filter onto the fuel pump.
2. Install a new clip.
Fig 19: Installing Fuel Pump Filter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP
1. Apply a light coat of gasoline or spindle oil to the O-ring.
  
  Fig 20: Installing Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Push the fuel pump into the fuel tank fuel filter.
NOTE: Make sure that the O-ring is not cracked or jammed when installing.

Fig 21: Pushing Fuel Pump Into Fuel Tank Fuel Filter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP CUSHION RUBBER
1. Install the fuel pump cushion rubber onto the fuel pump.
Fig 22: Installing Fuel Pump Cushion Rubber
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION SUPPORT NO.2
1. Align the claw positions, then install the fuel suction support No. 2 onto the fuel filter.
Fig 23: Installing Fuel Suction Support No.2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP HARNESS
1. Connect the pump harness connector.
2. Install the 2 pump harness terminals.
Fig 24: Installing Fuel Pump Harness
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION PLATE SUB-ASSY
1. Apply a light coat of gasoline or spindle oil to the O-ring of the fuel suction plate.
  
  Fig 25: Installing Fuel Suction Plate Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the claw positions, then install the fuel suction plate into the fuel filter.
  NOTE: Make sure that the O-ring is not cracked or jammed when installing.
3. Connect fuel pump harness connector.
  
  Fig 26: Connecting Fuel Pump Harness Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SENDER GAUGE ASSY
1. Slide the fuel sender gauge to fit the claws.
Fig 27: Installing Fuel Sender Gauge Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY
1. Install a new gasket onto the fuel suction with pump and gauge tube.
  
  Fig 28: Installing Fuel Suction W/ Pump & Gauge Tube Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the fuel suction with pump and gauge tube into the fuel tank.
  NOTE:
  - Do not damage the fuel pump filter.
  - Make sure that the fuel sender gauge arm does not bend.
  Fig 29: Installing Fuel Suction With Pump And Gauge Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the fuel tank vent tube set plate with the 6 bolts.
  1. Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf)
  Fig 30: Installing Fuel Tank Vent Tube Set Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the fuel tank protector plate with the 2 bolts.
  1. Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf)
  Fig 31: Installing Fuel Tank Protector Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the fuel tank main tube.
  1. Push the fuel tube joint into the plug of the suction plate, then install the tube joint clip.
  Fig 32: Installing Tube Joint Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Check that there are no scratches or foreign objects around the connected part 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 tank main tube cannot be pulled out.
CONNECT BATTERY NEGATIVE TERMINAL
1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
CHECK FOR FUEL LEAKAGE (See ON-VEHICLE INSPECTION )
NOTE: Check for fuel leaks with the fuel pump connector connected.
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Attach new butyl tape to the service hole cover.
2. Connect the wire to wire connector.
3. Connect the fuel pump connector.
4. Install the rear floor service hole cover, making sure it is aligned while aligning it with the 2 convex of the floor panel.
NOTE: Make sure that the rear floor service hole cover does not mount on the convex of the floor panel when installing.

Fig 33: Installing Rear Floor Service Hole Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RR SEAT CUSHION ASSY (See OVERHAUL )