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Installation [06/2016 - ]: Procedure

  1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 
    1. Set the new gasket to the fuel suction tube assembly with pump and gauge.
      GTY389637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Gasket
    2. Connect the fuel tank vent hose sub-assembly (Refer to PRECAUTION [06/2016 - ] ).
      NOTE:
      • When connecting the fuel tube connector, do not forcibly pull the fuel return vent tube sub-assembly.
      • Be careful not to bend the arm of the fuel sender gauge assembly.
    3. Insert the fuel suction tube assembly with pump and gauge inside the fuel tank assembly, and then attach the new gasket which has already been mounted on the fuel suction tube assembly with pump and gauge to the fuel tank assembly.
      GTY390987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Gaps or misplaced attachment of the gasket may cause fuel to leak, so make sure that there are no gaps or misalignments anywhere around the gasket when attaching it to the fuel tank assembly.

      GTY390886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply a light coat of gasoline to a gasket.
      GTY705270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Gasket
      *a Application area
      NOTE:
      • Apply gasoline in the area indicated in the illustration.
      • Ensure that gasoline does not adhere to the threads of the fuel tank assembly.
      • Check that there is no fuel or foreign matter in the seal section.
    5. Set the fuel suction tube assembly with pump and gauge within the fuel tank assembly installation position marks.
      GTY692938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Installation position marks
    6. Attach a new sheet ring and fuel pump gauge retainer, and temporarily tighten the fuel pump gauge retainer.
    7. Temporarily install SST (plate and 4 claws) to the fuel pump gauge retainer.
      • SST: 09808-14030 
        1. 09808-01030
        2. 09808-01050
      • SST: 09808-01071 
      NOTE:

      Do not apply a claw of SST at the marked part.

      GTY686952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Marked Part

      HINT: 

      • Be sure to use SST (claws) as shown in the illustration.
      • Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.
    8. While securely pressing SST (claws) against the fuel pump gauge retainer ribs, tighten the 4 bolts.

      HINT: 

      Install SST while pressing SST (claws) against the fuel pump gauge retainer (towards the center of SST).

    9. Using SST, tighten the fuel pump gauge retainer.
      GTY391548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      NOTE:
      • Do not use any tools other than those specified in this operation. Damage to the fuel pump gauge retainer or fuel tank may result.
      • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
      • Make sure to rotate SST horizontally. If SST is rotated at an angle, SST may come off.
      • Do not spin SST too fast or use an impact wrench as this may result in damage to components.
      • If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.
      • Check that the fuel suction tube assembly with pump and gauge position marks are within the fuel tank assembly installation position marks, as shown in the illustration.
      • After tightening to the specified torque, check that it has been tightened to the correct torque.

      HINT: 

      • Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing SST, rotate the handle slowly to tighten the fuel pump gauge retainer.
      • The tips of SST (claws) can be fitted onto the ribs of the fuel pump gauge retainer.
      TEXT IN ILLUSTRATION

      *a Position mark
      *b Installation position marks
    10. Connect the fuel tank main tube (Refer to PRECAUTION [06/2016 - ] ).
  2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 3

  3. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  4. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel suction tube assembly with pump and gauge connector.
    2. Install the No. 2 rear floor service hole cover with new butyl tape.
  5. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSEMBLY LH 

    Refer to PROCEDURE - Step 18

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