Installation [08/2016 - ]: Procedure

INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

Apply a co-rotation prevention check mark to the fuel suction with pump and gauge tube assembly.

HINT:

Perform this procedure when replacement of the fuel suction with pump and gauge tube assembly is necessary.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Co-rotation Prevention Check Mark
	Front Side of Vehicle

Apply a light coat of gasoline or grease to a new gasket and install the gasket to the fuel tank sub-assembly.

Set the fuel suction with pump and gauge tube assembly to the fuel tank sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Protrusion
*b	Groove

NOTE:

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

HINT:

Align the cutout of the fuel suction with pump and gauge tube assembly to the groove of the fuel tank sub-assembly.

Temporarily place the fuel pump gauge retainer by aligning the rotational start point mark of a new fuel pump gauge retainer with the rotational start point mark of the fuel tank sub-assembly while pressing the fuel suction with pump and gauge tube assembly into the fuel tank sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Rotational Start Point Mark (Fuel Tank Sub-assembly Side)
*b	Rotational Start Point Mark (Fuel Pump Gauge Retainer Side)
	Front Side of Vehicle

Set 4 SSTs (claw sets) to the fuel pump gauge retainer and temporarily install.

SST: 09808-14031
1. 09808-01080
2. 09808-01090
3. 09808-01100

NOTE:

Align the cutout of SST (claw set) to the rib of the fuel pump gauge retainer.
Do not place SST on the rotational start point mark of the fuel pump gauge retainer, otherwise SST (claw set) cannot be set correctly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Fuel Pump Gauge Retainer
*a	SST (Claw Set)
*b	Rib
*c	Cutout
*d	SST (Claw Set) Incorrect Installation Point (Rotational Start Point Mark of Fuel Pump Gauge Retainer)

While firmly pressing the claw of SST (claw set) into rib of the fuel pump gauge retainer, tighten the bolt.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Fuel Pump Gauge Retainer
*a	SST (Claw Set)
*b	Hook
	Press
	SST (Bolt)

Temporarily install SST (plate) to SST (claw set) with 4 SSTs (bolts).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	SST (Plate)
*b	SST (Claw Set)
	SST (Bolt)

Adjust the position of SST (plate) so that the setting hole of SST (handle) aligns with the center of the fuel pump gauge retainer.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Center of Fuel Pump Gauge Retainer
*b	SST (Plate)
	Front Side of Vehicle

While firmly pressing the SST (claw set) into rib of the fuel pump gauge retainer, tighten SST (bolt).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Fuel Pump Gauge Retainer
*a	SST (Plate)
*b	SST (Claw Set)
*c	SST (Bolt)
*d	Rib
	Press

While one person presses the fuel suction with pump and gauge tube assembly into the fuel tank sub-assembly, have another person firmly press the fuel pump gauge retainer into the threads of the fuel tank sub-assembly and tighten approximately one and a half turns.

NOTE:

Do not use any tools other than SST, such as a screwdriver, etc.
Do not use excessive force when pressing down on SST, as the fuel suction with pump and gauge tube assembly will place excessive force on the pump gauge retainer and be difficult to remove, and parts may be damaged.
Do not use an impact wrench or turn the SST handle with excessive force, as parts may be damaged.
Do not rotate the fuel pump gauge retainer when the co-rotation prevention check mark is out of place.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Co-rotation Prevention Check Mark
*b	Tightening Start Position
*c	One and Half Rotation Position
	Front Side of Vehicle

While one person presses the fuel suction with pump and gauge tube assembly into the fuel tank sub-assembly, have another person slowly tighten approximately 180°.

*a	SST (Plate)
*b	Person in Charge of Tightening
*c	Person in Charge of Supporting
*d	Approximately 180°
	Front Side of Vehicle

Check the tightening condition of the fuel pump gauge retainer.

Using a vernier caliper, measure the upper surface dimensions of the fuel tank sub-assembly at the 3 positions as shown in the illustration.

Standard

Measurement difference is within 3 mm.

NOTE:

If the measurement difference is approximately 6 mm, the threads misaligned by 1 threads (6 mm) and the fuel pump gauge retainer must be installed again.

*1	Fuel Pump Gauge Retainer
*2	Fuel Tank Sub-assembly
*a	Vernier Caliper
*b	Measurement Position
*c	Measurement Height
	Front Side of Vehicle

Install SST (handle) to SST (plate).

SST: 09808-14031
1. 09808-01010
2. 09808-01020

*a	SST (Handle)
*b	SST (Plate)
*c	Tightening Complete Position
*d	Rotational Start Point Mark of Fuel Pump Gauge Retainer
*e	Rotational Start Point Mark of Fuel Tank Sub-assembly
*f	Person in Charge of Tightening
*g	Person in Charge of Supporting
	Tighten

While one person presses the fuel suction with pump and gauge tube assembly onto the fuel tank sub-assembly, have another person use SST (handle) and slowly tighten the fuel pump gauge retainer until it reaches the tightening complete position.

INSTALL FUEL TANK SUB-ASSEMBLY
1. Install the fuel tank sub-assembly.
  Refer to INSTALLATION [09/2015 - ]