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Installation [11/2016 - ]: Procedure

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  1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    1. Install a new fuel suction tube set gasket to the fuel tank assembly.
    2. Set the fuel suction tube with pump and gauge assembly to the fuel tank assembly.
      GTY684521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Notch
      NOTE:

      Be careful not to bend the arm of the fuel sender gauge assembly.

      HINT: 

      Align the protrusion of the fuel suction tube with pump and gauge assembly with the notch of the tank suction tube support.

  2. INSTALL FUEL PUMP GAUGE RETAINER 
    1. Align the triangle mark on a new fuel pump gauge retainer with the "S" mark on the fuel tank assembly and while pushing down the fuel suction tube with pump and gauge assembly, attach the fuel pump gauge retainer.
      GTY621712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a "S" Mark
      *b Triangle Mark
    2. Install SST (fuel pump retainer tool assy) to the fuel pump gauge retainer.
      1. Insert 2 SST (claw) between the service hole and fuel pump gauge retainer, and adjust the position so that the protrusions of the fuel pump gauge retainer are aligned with the grooves of SST (claw) as shown in the illustration.
        GTY630037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw) *b Triangle Mark
        *c Protrusion of Fuel Pump Gauge Retainer *d Groove of SST (Claw)
        *e Correct *f Incorrect
        • SST: 09808-14040 
          1. 09882-14040
        NOTE:

        Ensure that SST (claw) does not cover the triangle mark of the fuel pump gauge retainer.

      2. While ensuring that SST (plate) is centered, install SST (plate) to 2 SST (claw) with 2 SST (bolt and washer set).
        GTY638484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw)
        *b SST (Plate)
        *c SST (Bolt and Washer Set)
        • SST: 09808-14040 
          1. 09881-14040
          2. 09883-14040
    3. While lightly pushing down on SST (fuel pump retainer tool assy), tighten the fuel pump gauge retainer by 1 and a half turns so that the triangle mark on the fuel pump gauge retainer is positioned between the "SERVICE" range on the fuel tank assembly.
      GTY654525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Fuel Pump Retainer Tool Assy)
      *b Triangle Mark
      *c "SERVICE" Range
      NOTE:
      • Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.
      • Do not push down on SST (fuel pump retainer tool assy) excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
      • Make sure to turn the breaker bar horizontally. If it is turned at an angle, SST (fuel pump retainer tool assy) may come off.
      • Do not spin SST (fuel pump retainer tool assy) too fast or use an impact wrench as this may damage components.
      • If SST (fuel pump retainer tool assy) comes off of the fuel pump gauge retainer, loosen SST (bolt and washer set) and reinstall SST (fuel pump retainer tool assy).

      HINT: 

      While pushing down on SST (fuel pump retainer tool assy), turn the fuel pump gauge retainer clockwise to tighten. Make sure that the detent of the tank suction tube support does not move out of the groove of the fuel tank assembly.

  3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Push the fuel tube joint onto the plug of the fuel suction plate sub-assembly, then install the tube joint clip.
      GTY663882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-ring
      *c Collar
      *d Correct
      *e Incorrect
      NOTE:
      • Check that there are no scratches or foreign matter around the connecting parts 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 sub-assembly is securely connected by pulling on it.
  4. CHECK AIRTIGHTNESS 
    1. After installing the fuel suction tube with pump and gauge assembly, check for fuel leaks by first applying soapy water to the area where the fuel suction plate sub-assembly and fuel pump gauge retainer contact, and then blow forcefully into the fuel inlet area through a flexible pouring spout or similar tube.
      GTY727085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Blow forcefully until the reverse flow prevention valve inside the fuel inlet activates.
      NOTE:

      Be careful not to inhale any fuel vapor.

      HINT: 

      There should be a faintly audible sound when the reverse flow prevention valve operates.

    3. If improper installation of the fuel suction tube with pump and gauge assembly, etc. has resulted in a condition where fuel will leak, air will leak out as shown in the illustration.
      GTY685649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Air Bubbles
      NOTE:

      If air leaks out, recheck the installation condition, and replace the fuel pump gauge retainer and fuel suction tube set gasket with new ones. Also, make sure to fully wipe away the soapy water. (Any remaining soapy water can cause the fuel suction tube set gasket to slip and result in an improper seal.)

  5. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.
    2. Clean the installation surfaces of the rear floor service hole cover and vehicle body.
    3. Connect the 2 fuel pump connectors.
    4. Install the rear floor service hole cover with new butyl tape.
      NOTE:

      Securely install the rear floor service hole cover.

      GTY739709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Butyl Tape Adhesion Area
    5. Return the front floor carpet to its original position.
  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [11/2016 - ]

  7. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  8. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH 

    Refer to PROCEDURE - Step 23

  9. INSTALL ROPE HOOK (for LH Side) 

    Refer to PROCEDURE - Step 24

  10. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (for LH Side) 

    Refer to PROCEDURE - Step 25

  11. INSTALL DECK TRIM POCKET COVER (for LH Side) 

    Refer to PROCEDURE - Step 26

  12. CONNECT REAR NO. 2 SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 11

  13. INSTALL DECK TRIM SIDE SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 28

  14. INSTALL NO. 2 DECK SIDE TRIM COVER 

    Refer to PROCEDURE - Step 29

  15. CONNECT REAR NO. 1 SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 14

  16. INSTALL FRONT DECK SIDE TRIM COVER LH 

    Refer to PROCEDURE - Step 31

  17. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH 

    Refer to PROCEDURE - Step 34

  18. INSTALL ROPE HOOK (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

  19. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

  20. INSTALL DECK TRIM POCKET COVER (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

  21. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 2

  22. INSTALL SIDE TRIM COVER RH (w/o Rear Automatic Air Conditioning System) 

    Refer to PROCEDURE - Step 39

  23. INSTALL COOLER (NO. 2 ROOM TEMP. SENSOR) THERMISTOR (w/ Rear Automatic Air Conditioning System) 

    Refer to PROCEDURE - Step 1

  24. CONNECT REAR NO. 2 SEAT OUTER BELT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  25. INSTALL DECK TRIM SIDE BELT HOLE COVER RH 

    Refer to PROCEDURE - Step 42

  26. INSTALL NO. 1 DECK SIDE TRIM COVER 

    Refer to PROCEDURE - Step 43

  27. CONNECT REAR NO. 1 SEAT OUTER BELT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  28. INSTALL FRONT DECK SIDE TRIM COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  29. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 

    Refer to PROCEDURE - Step 49

  30. INSTALL REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 50

  31. INSTALL REAR OUTER SEAT TRACK BRACKET COVER LH 

    Refer to PROCEDURE - Step 4

  32. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 

    Refer to PROCEDURE - Step 59

  33. INSTALL REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

  34. INSTALL REAR OUTER SEAT TRACK BRACKET COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  35. INSTALL REAR NO. 2 SEAT ASSEMBLY 

    Refer to INSTALLATION [11/2016 - ]

  36. INSTALL REAR FLOOR FINISH PLATE 

    Refer to PROCEDURE - Step 67

  37. INSTALL REAR DECK FLOOR BOX 

    Refer to PROCEDURE - Step 68

  38. INSTALL DECK SIDE TRIM BOX LH 

    Refer to PROCEDURE - Step 69

  39. INSTALL NO. 3 DECK BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 70

  40. INSTALL DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 71

  41. INSTALL REAR NO. 1 SEAT ASSEMBLY 

    for Captain Seat Type: Refer to INSTALLATION [12/2013 - ]

    for 60/40 Split Seat Type LH Side: Refer to INSTALLATION [12/2013 - ]

    for 60/40 Split Seat Type RH Side: Refer to INSTALLATION [12/2013 - ]

  42. PERFORM INITIALIZATION 
    1. Perform "Inspection After Repair" after replacing the fuel pump.

      Refer to INITIALIZATION [11/2016 - ]

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