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Fuel Pump: Installation

  1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY 
    1. Apply a light coat of gasoline to 2 new O-rings, and install them to the fuel pressure regulator.
      Fig 1: Installing O-Rings To Fuel Pressure Regulator
      G04044604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel pressure regulator to the fuel relief valve.
    3. Install the clip to the relief valve.
    Fig 2: Installing Clip To Relief Valve
    G04044605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL JET PUMP 
    1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and jet pump to the fuel relief valve assembly.
    Fig 3: Installing O-Ring & Jet Pump To Fuel Relief Valve Assembly
    G04044606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL RELIEF VALVE ASSEMBLY 
    1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and fuel relief valve assembly to the fuel filter.
    Fig 4: Installing O-Ring & Fuel Relief Valve Assembly To Fuel Filter
    G04044607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FLANGE ASSEMBLY 
    1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and flange assembly to the fuel filter.
    Fig 5: Installing O-Ring & Flange Assembly To Fuel Filter
    G04044608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL PUMP 
    1. Install the fuel pump spacer to the fuel pump.
    2. Apply a light coat of gasoline to a new seal, and install it to the fuel pump.
    3. Install the fuel pump to the fuel filter.
      Fig 6: Installing New Seal To Fuel Pump
      G04044609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 2 connectors and terminal.
    Fig 7: Connecting Connectors & Terminal
    G04044610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO.1 FUEL SUB-TANK 
    1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and No. 1 fuel sub-tank to the fuel filter with flange assembly.
      Fig 8: Installing O-Ring & No. 1 Fuel Sub-Tank To Fuel Filter With Flange Assembly
      G04044611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the jet pump nozzle to the No. 1 fuel subtank.
      Fig 9: Connecting Jet Pump Nozzle To No. 1 Fuel Subtank
      G04044612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new E-ring.
    Fig 10: Installing New E-Ring
    G04044613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL SENDER GAUGE ASSEMBLY 
    1. Set the fuel sender gauge to the No. 1 fuel sub-tank. Then slide the sender gauge downward to install it.
    2. Connect the fuel sender gauge connector.
    Fig 11: Installing Fuel Sender Gauge Assembly
    G04044614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Install a new gasket onto the fuel tank.
    2. Connect the fuel hose with the clip.
    3. Set the fuel suction tube to the fuel tank.
      Fig 12: Connecting Fuel Hose With Clip
      G04044615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the fuel sender gauge arm does not bend.
      • Do not damage the No. 2 fuel hose.
    4. Align the protrusion of the fuel suction tube and the cutout of the fuel tank vent tube set plate.
    5. While holding the fuel suction tube by hand, install the fuel tank vent tube to the fuel tank with the 8 bolts.
      Fig 13: Installing Fuel Tank Vent Tube To Fuel Tank
      G04044616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

    6. Connect the fuel tube.
      1. Push the fuel tube joint in the plug of the fuel suction plate, then install the 2 tube joint clips.
        Fig 14: Installing Fuel Tube Joint Clips
        G04044617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • 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 tube joint clips are on the collars of the fuel tube joints.
        • After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
        • Be careful not to damage any clips. If a clip is damaged, replace it.
    7. Connect the fuel suction tube connector.
  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See Step 93 in  INSTALLATION  ) 
  10. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION   ) 
  11. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER 
    1. Install the No. 2 rear floor service hole cover with new butyl tape.
    Fig 15: Installing No. 2 Rear Floor Service Hole Cover
    G04044618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL REAR SEAT CUSHION ASSEMBLY (See Step 4 in  INSTALLATION  ) 
  13. PERFORM INITIALIZATION 
    1. Perform initialization (See INITIALIZATION ).

      HINT:

      Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.

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