Fuel Pump: Installation: Procedure

HINT: 

• The fuel pump unit will rotate and cannot be secured in the specified position if there is any gasoline on the packing. Thoroughly wipe away all gasoline from the packing.
• Make the markings to be easily visible when the fuel pump cap is installed.
• Marks are provided on the fuel pump unit and fuel tank for correct installation of the fuel pump unit.

1. Mark the fuel pump cap and the fuel tank at the point where the threading of each part begins as shown in the figure.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Fuel Pump Unit
   *b	Fuel Pump Cap
   *c	Fuel Tunk
   *d	Fuel Pump Cap Marking
   *e	Fuel Tunk Marking
   *f	Threading Start Point

2. Align the fuel tank alignment mark with the fuel pump unit as shown in the figure.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Fuel Pump Unit
   *b	Fuel Pump Unit Alignment Mark
   *c	Fuel Tunk Alignment Mark

3. Align the fuel tank and fuel pump cap markings.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Fuel Pump Cap
   *b	Fuel Pump Cap Marking
   *c	Fuel Tunk Marking

4. Rotate the fuel pump cap counterclockwise until the cap marking is approx. 15° away from the fuel tank marking as shown in the figure.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Fuel Pump Cap
   *b	Fuel Pump Cap Marking
   *c	Fuel Tunk Marking
   *d	15°

5. While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 180° clockwise.
   NOTE:

   The cap could be damaged if the SST (wrench) is used with any play between the cap and the SST (wrench). Securely install the SST (wrench) so that there is no gap between the SST (wrench) tabs and the side of the cap.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Fuel Pump Cap
   *b	Fuel Pump Cap Marking
   *c	180°

6. Set the SST (wrench) as shown in the figure.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 49F042001 

   HINT: 

   The total rotation angle is 450 to 495 ° if the approx. 180° from Step f is included.

7. Using the SST (wrench), tighten the fuel pump cap within the specified rotation angle and cap tightening torque without shifting the fuel tank and fuel pump unit alignment marks.

   Rotation angle

   270 to 315°

   Fuel pump cap tightening torque 

   Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

   HINT: 

   • The total rotation angle is 450 to 495 ° if theapprox.180 ° from Step f is included.
   • If the specified tightening torque cannot be obtained, replace the fuel pump cap and packing.
   • If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and packing, replace the fuel tank.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Fuel Pump Cap Marking
   *b	450°
   *c	495°

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Fuel Pump Cap
   *b	Fuel Pump Cap Marking
   *c	Fuel Pump Unit Alignment Mark
   *d	Fuel Tunk Alignment Mark
   *e	270°
   *f	315°

1. Install the packing.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Fuel Pump Unit Connector
   *2	Fuel Tube Connector (Quick Type)
   *3	Fuel Pump Cap
   *4	Fuel Pump Unit
   *5	Packing
   *a	Vehicle Front
   	N*m (kgf*cm, ft.*lbf): Specified torque
   •	Non-reusable part

2. Install the fuel pump unit.
3. Install the fuel pump cap.

   See step  1

   Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

4. Install the fuel tube connector (quick type).

   Refer to INSTALLATION 

5. Install the fuel pump unit connector.
6. Install the service hole cover.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Service Hole Cover

7. Install the rear seat cushion.

   Refer to INSTALLATION

8. Connect the negative battery cable.

   Refer to INSTALLATION

9. Complete the "AFTER SERVICE PRECAUTION".

   Refer to PROCEDURE - Step 1