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Fuel Pump: Installation

NOTE: Always use "Torx" socket wrench E10 when installing the rear seat.
  1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Install a new fuel suction tube gasket onto the fuel tank.
      Fig 1: Locating Fuel Suction Tube Gasket
      G04829078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the protrusion of the fuel pump with the cutout of the fuel tank and install the fuel suction with pump and gauge tube assembly.
      NOTE: The arm of the sender gauge should not be bent.
      Fig 2: Aligning Protrusion Of Fuel Pump With Cutout Of Fuel Tank
      G04829098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL PUMP GAUGE RETAINER 
    1. Using SST, turn the retainer 540° clockwise from the screw starting point and align the claw of the retainer with the matchmark on the fuel tank.

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      NOTE: Replace the fuel pump gauge retainer with a new one if not installed properly.

      Part No. 77144-52040 

      HINT:

      • Align the claws of the fuel pump gauge retainer with the tips of SST.
      • At the point where the retainer is turned 90° from the start of the thread, push the retainer in from the opposite side to the start of the thread. Check that the thread of the retainer is properly engaged with that on the tank.
        Fig 3: Identifying Fuel Pump Gauge Retainer
        G04829099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Connect the fuel tank vent hose.
      Fig 4: Identifying Fuel Tank Vent Hose
      G04829100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Insert the fuel tank main tube.
    2. Install the tube joint clip.
      NOTE:
      • Check that there are no scratches or foreign matter on the connecting parts.
      • Check that the fuel tube joint is inserted securely.
      • After installing the tube joint clip, check that the fuel tube joint has not been pulled off.
      • Do not damage any clips. If a clip is damaged, replace it.
      Fig 5: Locating Fuel Tank Main Tube Sub-Assembly
      G04829101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel pump connector.
      Fig 6: Locating Fuel Pump Assembly Connector
      G04829019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear service hole cover with new butyl tape.
      Fig 7: Locating Rear Service Hole Cover With Butyl Tape
      G04829103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL REAR SEAT ASSEMBLY (for Hatchback) (See  INSTALLATION  ) 
  7. INSTALL REAR SEAT LEG COVER NO. 2 (for Hatchback) (See  INSTALLATION  ) 
  8. INSTALL REAR SEAT LEG COVER NO. 1 (for Hatchback) (See  INSTALLATION  ) 
  9. INSTALL DECK FLOOR BOX (for Hatchback) (See  INSTALLATION  ) 
  10. INSTALL DECK BOARD SUB-ASSEMBLY (for Hatchback) (See  INSTALLATION  ) 
  11. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Hatchback) (See  INSTALLATION  ) 
  12. INSTALL REAR SEAT CUSHION COVER PAD (for Sedan) (See  INSTALLATION  ) 
  13. INSTALL REAR SEAT CUSHION COVER PAD (for Hatchback) (See  INSTALLATION  ) 
  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  15. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION   ) 
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