Fuel Pump: Installation

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL FUEL PUMP ASSEMBLY
1. Connect the pump harness connector.
  
  Fig 1: Identifying Pump Harness Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply gasoline to a new O-ring and install the O-ring to the fuel filter.
  
  Fig 2: Identifying Fuel Filter Pump O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Attach the 5 claws to the claw holes and install the fuel pump.
INSTALL BRACKET
1. Attach the 2 claws to the claw holes and install the bracket.
  
  Fig 3: Identifying Bracket Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUB-TANK ASSEMBLY
1. Apply gasoline to a new O-ring and install it to the jet pump.
  
  Fig 4: Applying Gasoline O-Ring And Installing Jet Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the jet pump while aligning it to the installation position of the sub-tank.
  
  Fig 5: Aligning Jet Pump To Position Of Sub-Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the jet pump nozzle.
4. Attach the 2 claws to the claw holes and install the fuel sub-tank.
  
  Fig 6: Identifying Sub-Tank Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the wire harness.
  
  Fig 7: Identifying Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the spring to the fuel suction plate shaft and install them to the sub-tank.
  
  Fig 8: Identifying Springs From Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using needle-nose pliers, install a new E-ring.
  HINT:
  
  Slightly lower the sub-tank to install the E-ring.
  
  Fig 9: Removal/Installation Of E-Ring Using Needle Nose Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION WITH PUMP ASSEMBLY
1. Install a new gasket onto the fuel pump.
  
  Fig 10: Identifying Gasket From Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the fuel hose and install the fuel pump into the fuel tank.
  NOTE: Do not damage the fuel pump filter.
  
  Fig 11: Connecting Fuel Hose And Installing Fuel Pump Into Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK VENT TUBE SET PLATE
1. Install the set plate with the 8 bolts.
  Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)
  
  Fig 12: Identifying Bolts And Set Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Install the fuel tube with the joint clips.
  
  Fig 13: Installing Fuel Tube With Joint Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  CAUTION:
  - Check that there are no scratches or foreign objects on the connecting parts.
  - Check that the fuel tube joint is inserted securely.
  - Check that the fuel tube joint clip is on the collars of the fuel tube joint.
  - After installing the tube joint clip, check that the fuel tube joint has not been pulled off.
  - Be careful not to damage the clip. If the clip is damaged, replace it.
INSTALL FUEL TANK ASSEMBLY
1. Install the fuel tank (see REASSEMBLY ).
  
  Fig 14: Identifying Fuel Tank Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002