Fuel Pump: Installation

INSTALL FUEL PUMP ASSEMBLY
1. Connect the fuel pump connector.
  
  Fig 1: Locating Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the fuel pump spacer to the fuel pump assembly.
3. Apply gasoline to a new O-ring and install the O-ring to the fuel filter.
  
  Fig 2: Identifying Fuel Pump Spacer And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Attach the 5 claws to the holes to install the fuel pump.
  
  Fig 3: Identifying Main Fuel Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FUEL SUCTION SUPPORT
1. Attach the 2 claws to the holes to install the No. 1 fuel suction support.
  
  Fig 4: Locating No. 1 Fuel Suction Support Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FUEL SUB-TANK
1. Apply gasoline to a new O-ring and install it to the jet pump.
  
  Fig 5: Identifying Jet Pump And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the jet pump while aligning it with the installation position on the No. 1 fuel sub-tank.
3. Install the jet pump nozzle.
  
  Fig 6: Installing Jet Pump Nozzle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Attach the 2 claws to the holes to install the No. 1 fuel sub-tank.
  
  Fig 7: Installing No. 1 Fuel Sub-Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the wire harness.
  
  Fig 8: Connecting Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. for TMC Made:
  Install the springs to the fuel suction plate shafts, and then install them to the No. 1 fuel sub-tank.
  
  Fig 9: Installing Spring To Fuel Suction Plate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. for TMMC Made:
  Install the spring to the fuel suction plate shaft, and then install it to the No. 1 fuel sub-tank.
  
  Fig 10: Installing Spring To Fuel Suction Plate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using needle-nose pliers, install a new E-ring.
  HINT:
  
  Slightly lower the fuel suction plate to install the E-ring.
  
  Fig 11: Installing E-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION WITH PUMP ASSEMBLY
1. Install a new gasket onto the fuel suction plate.
  
  Fig 12: Identifying Fuel Suction Plate Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the fuel hose with the paint mark facing towards the top of the vehicle, and then secure the clip.
3. Install the fuel suction with pump into the fuel tank.
  NOTE: Do not damage the fuel suction with pump.
  
  Fig 13: Connecting Fuel Hose With Paint Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK VENT TUBE SET PLATE
1. Install the set plate and tube clamp with the 8 bolts.
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 14: Locating Set Plate With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Connect the fuel main tube with the tube joint clip.
  
  Fig 15: Connecting Fuel Main Tube With Tube Joint Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Check that there are no scratches or foreign matter on the connecting parts.
  - Check that the fuel tube joint is inserted securely.
  - Check that the fuel tube joint clip is on the collar of the fuel tube joint.
  - After installing the tube joint clip, check that the fuel tube joint cannot be 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 assembly (See REASSEMBLY ).
  
  Fig 16: Identifying Correct And Incorrect Position Of Fuel Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002