Installation [12/2013 - ]: Procedure

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Protrusion
   *b	Notch

   NOTE:

   Make sure that the fuel sender gauge arm does not bend.

   HINT: 

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

1. Align the triangle mark on new fuel pump gauge retainer with the "S" mark on the fuel tank assembly while pushing down the fuel suction tube with pump and gauge assembly, attach the fuel pump gauge retainer.

   Courtesy 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.

      Courtesy 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 the 2 SST (bolt and washer set).

      Courtesy 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 "475" and "535" marks on the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	SST (Fuel Pump Retainer Tool Assy)
   *b	Triangle Mark
   *c	"535" Mark
   *d	"475" Mark

   NOTE:

   • Do not use any tools other than specified in this operation 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 the SST (bolt and washer set) and reinstall SST (fuel pump retainer tool assy).

   HINT: 

   While pushing down 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.

1. Push the fuel tube joint onto the plug of the fuel suction plate sub-assembly, then install the tube joint clip.

   Courtesy 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.

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.

   Courtesy 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Air Bubbles

   NOTE:

   If air leaks out, recheck the installation condition, and replace the used 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.)

1. Connect the fuel pump connector.
2. Install the rear floor service hole cover with new butyl tape.
3. Install the front floor carpet.

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Refer to INSTALLATION [12/2013 - 11/2016] , or refer to INSTALLATION [11/2016 - ]

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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 - ]

Refer to PROCEDURE - Step 1

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

   Refer to INITIALIZATION [12/2013 - ]