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.
3. Attach the 5 claws to the claw holes and install the fuel pump.
  
  Fig 2: Identifying Claws To Claw Holes And Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRACKET
1. Attach the 2 claws to the claw holes and install the bracket.
  
  Fig 3: Identifying Claws To Claw Holes And Bracket
  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 To Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the jet pump while aligning it with the installation position of the sub-tank.
  
  Fig 5: Aligning Jet Pump With 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 Fuel Sub-Tank Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the wire harness.
  
  Fig 7: Connecting Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the springs to the fuel suction plate shafts and install them to the sub-tank.
  
  Fig 8: Fuel Suction Plate Shafts Springs
  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: Identifying E-ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION WITH PUMP ASSEMBLY
1. Install a new gasket onto the fuel pump.
  
  Fig 10: Identifying Fuel Pump Gasket
  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: 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 Set Plate With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Install the fuel tank main tube with the joint clip (see Fig 14).
  
  Fig 13: Installing Fuel Tank Main Tube With Joint Clip
  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 ).