Removal & Installation and Disassembly & Reassembly

1. Remove the rear floor service hole cover.
2. Disconnect the vapor pressure sensor connector.
3. Disconnect the fuel pump connector.
   Fig 1: Removing Rear Floor Service Hole Cover

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1. Remove the tube joint clip, then pull out the fuel pump tube.
   Fig 2: Removing Tube Joint Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check around the connector for dirt or mud before this operation. Remove the dirt if necessary.
   • Be careful of mud because the fuel tube joint has an O-ring which seals the pipe and connector that can be contaminated.
   • Do not use any tools in this operation.
   • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
   • When the pipe and connector are stuck, push and pull the connector to release. Pull the connector carefully.

   Fig 3: Identifying Fuel Suction W/ Pump & Gauge Tube Assy Components

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 8 bolts, then remove the fuel tank vent tube set plate.
   Fig 4: Removing Fuel Tank Vent Tube Set Plate

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3. Remove the fuel suction tube w/ pump & gauge from the fuel tank.
   NOTE:

   • Do not damage the fuel pump filter.
   • Do not bend the arm of the fuel sender gauge.
   • Remove the gasket from the fuel suction tube w/ pump & gauge.
     Fig 5: Removing Fuel Suction Tube W/ Pump & Gauge From Fuel Tank

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the cover.
2. Remove the tube joint clip, then pull out the vapor pressure sensor.
   Fig 6: Removing Tube Joint Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver with the tip wrapped in tape, unfasten the 5 claws. Then remove the fuel suction support No. 2.
   NOTE: Do not damage the fuel suction support No. 2.
Fig 7: Unfastening Claws
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1. Disconnect the fuel sender gauge connector.
2. Using a screwdriver with the tip wrapped in tape, unfasten the clamp to release the fuel sender gauge. Then slide the fuel sender gauge to remove it from the fuel pump.
   Fig 9: Disconnecting Fuel Sender Gauge Connector

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1. Disconnect the fuel pump connector.
2. Using a screwdriver with the tip wrapped in tape, unfasten the 4 claws. Then pull out the fuel suction plate.
   Fig 10: Unfastening Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Do not damage the fuel suction plate.

1. Disconnect the connector.
2. Using a small screwdriver, pry out the fuel pump harness.
   Fig 11: Disconnecting Connector For Fuel Pump Harness

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1. Pull out the fuel pump from the fuel tank fuel filter.
   Fig 12: Pulling Out Fuel Pump From Fuel Tank Fuel Filter

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1. Using a small screwdriver, pry out the clip.
2. Pull out the fuel pump filter from the fuel pump.
   Fig 13: Prying Out Clip For Fuel Pump Filter

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1. Pull out the fuel pressure regulator from the fuel tank fuel filter.
2. Remove the O-ring from the fuel pressure regulator.
   Fig 14: Removing O-Ring From Fuel Pressure Regulator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light coat of spindle oil or gasoline to a new O-ring, then install it to the fuel pressure regulator.
2. Push in the fuel pressure regulator to the fuel tank fuel filter.
   Fig 15: Installing O-Ring To Fuel Pressure Regulator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the fuel pump filter with a new clip.

1. Apply a light coat of gasoline or spindle oil to the O-ring on the fuel pump.
Fig 16: Installing O-Ring On Fuel Pump
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Push in the fuel pump to the fuel tank fuel filter.

1. Install the vapor pressure sensor with the tube joint clip.
   NOTE:

   • Check the connected part for scratch or foreign objects.
   • Check that the vapor pressure sensor is inserted securely.
   • Check that the tube joint clip is on the collar of the vapor pressure sensor.
   • After installing the tube joint clip, check that the vapor pressure sensor has not been pulled off.
     Fig 17: Installing Vapor Pressure Sensor With Tube Joint Clip

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cover.

1. Install a new gasket to the fuel suction tube w/ pump & gauge.
2. Install the fuel suction tube w/ pump & gauge to the fuel tank.
   NOTE:

   • Do not damage the fuel pump filter.
   • Do not bend the arm of the fuel sender gauge.
3. Align the mark of the fuel tank vent tube set plate with the fuel suction tube w/ pump & gauge.
4. Install the fuel tank bent tube set plate with the 8 bolts.

   Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf) 

   Fig 18: Installing Fuel Tank Bent Tube Set Plate & Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the fuel pump tube with the tube joint clip.
   NOTE:

   • Check the connected part for scratch or foreign objects.
   • 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 19: Installing Fuel Pump Tube With Tube Joint Clip

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Connect the fuel pump connector.
2. Connect the vapor pressure sensor connector.
3. Using new butyl tape, install the rear floor service hole cover.
   Fig 20: Installing Rear Floor Service Hole Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002