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Installation [06/2015 - ]: Procedure

  1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    1. Install a new fuel suction tube set gasket to the fuel tank assembly.
      GTY484592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Suction Tube Set Gasket
    2. Set the fuel suction tube with pump and gauge assembly to the fuel tank assembly.
      GTY487265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Notch
      *b Protrusion
      NOTE:

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

    3. Align the protrusions of the fuel suction tube with pump and gauge assembly with the notches of the fuel tank assembly.
    4. Place a paint mark on the fuel suction tube with pump and gauge assembly as shown in the illustration.
      GTY483727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark

      HINT: 

      Perform this step only when replacing the fuel suction tube with pump and gauge assembly.

  2. INSTALL FUEL PUMP GAUGE RETAINER 
    1. Install SST to a new fuel pump gauge retainer.
      1. Temporarily install SST (plate), SST (claw) and SST (bolt) to the fuel pump gauge retainer.
        GTY485889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw)
        *b SST (Plate)
        *c SST (Bolt)
        *d Narrow
        *e Wide
        *f Correct
        *g Incorrect
        • SST: 09808-14030 
          1. 09808-01020
          2. 09808-01030
          3. 09808-01050
        • SST: 09808-01071 
        NOTE:
        • Install SST (claw) to the correct location.
        • Do not install SST (claw) to a location where the pitch between ribs of the fuel pump gauge retainer is narrow.
      2. Adjust the position of SST (claw) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.
        GTY483814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Center Point of Fuel Pump Gauge Retainer
      3. Press SST (claw) against the rib of the fuel pump gauge retainer and tighten SST (bolt).
    2. While pressing down on the fuel suction tube with pump and gauge assembly, have another person align the start of the threads of the fuel pump gauge retainer with the start of threads mark that was copied onto the vehicle body.
      GTY486777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d Front
      *e Press down
      *f Start of Threads of the Fuel Pump Gauge Retainer
      *g Copy of Start of Threads Mark
      *h Align
    3. While pressing down on the fuel suction tube with pump and gauge assembly, have another person firmly press the fuel pump gauge retainer against the threads of the fuel tank assembly, and tighten the fuel pump gauge retainer by approximately 90°.
      GTY486882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Gauge Retainer
      *2 Fuel Tank Assembly
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d Front
      *e Tighten approximately 90°
      *f Fuel pump gauge retainer rises up
      *g Press quickly and firmly
      *h Cross Section
      *i Paint Mark
    4. Quickly and firmly press down on the part of the fuel pump gauge retainer closest to the rear of the vehicle to keep it from rising up.
      NOTE:
      • Be careful not to apply excessive downward force to SST, as this may damage the fuel suction tube with pump and gauge assembly or fuel tank assembly.
      • Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so be sure SST is horizontal when turning.
      • To prevent damage to parts, do not turn SST too vigorously.
      • If SST slips off of the fuel pump gauge retainer, loosen SST (bolt) and install SST again.
      • Do not turn the fuel pump gauge retainer if the paint marks become misaligned.

      HINT: 

      • If the fuel pump gauge retainer cannot be properly pressed down due to the position of SST, set SST in a different position.
      • When fully pressing down the fuel pump gauge retainer, there will be a sound or tactile sensation of parts contacting each other, and at this point the fuel suction tube with pump and gauge assembly will stop rising up.
    5. While pressing down on the fuel suction tube with pump and gauge assembly, have another person slowly tighten the fuel pump gauge retainer by approximately 180°.
      GTY487089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d One Person in Charge of Tightening
      *e One Person in Charge of Pressing Down
      *f Front
      *g Approximately 180°
    6. Check the tightening status of the fuel pump gauge retainer.
      GTY494230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front
      *b Measurement Position
      *c Vernier Caliper
      1. Using a vernier caliper, measure the distance from the fuel tank assembly to the upper surface of the fuel pump gauge retainer at 3 positions as shown in the illustration.

        Standard

        Difference between the 3 measured values is 3 mm (0.118 in.) or less.

        NOTE:

        If the difference between measurements is approximately 6 mm (0.236 in.), the threads are cross-threaded by 1 row (6 mm (0.236 in.)), so remove and reinstall the fuel pump gauge retainer.

    7. Install SST (handle) to SST (plate).
      • SST: 09808-14030 
        1. 09808-01010
        2. 09808-01020
        3. 09808-01030
        4. 09808-01050
      • SST: 09808-01071 
      GTY490353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d SST (Handle)
      *e One Person in Charge of Tightening
      *f One Person in Charge of Pressing Down
      *g Approximately 90°
      *h Front
    8. While pressing down on the fuel suction tube with pump and gauge assembly, have another person use SST (handle) to slowly tighten the fuel pump gauge retainer approximately 90°.
    9. GTY491288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Claw)
      *b SST (Plate)
      *c SST (Bolt)
      *d SST (Handle)
      *e Press down
      *f Pull
      *g Start of Threads of the Fuel Pump Gauge Retainer
      *h Copy of Fully Tightened Mark
      *i Front

      While pressing down on the center of SST (handle) to prevent SST from separating from the fuel pump gauge retainer, pull SST (handle) with another person pulling the opposite end of SST (handle), and slowly tighten the fuel pump gauge retainer until it reaches the fully tightened mark that was copied onto the vehicle body.

  3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Push the fuel tube joint onto the plug of the fuel suction plate sub-assembly, then install the tube joint clip.
      GTY491696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Tube Joint Clip *2 Fuel Tank Main Tube Sub-assembly
      *a Fuel Tube Joint *b O-ring
      *c Collar *d Correct
      *e Incorrect - -
      NOTE:
      • Check that there are no scratches or foreign matter around the connecting parts of the fuel tube joint and plug before performing this work.
      • Check that the fuel tube joint is securely inserted to the end.
      • Check that the tube joint clip is on the collar of the fuel tube joint as shown in the illustration.
      • After installing the tube joint clip, check that the fuel tank main tube sub-assembly is securely connected by pulling on it.
  4. CHECK AIRTIGHTNESS 
    1. After installing the fuel suction tube with pump and gauge assembly, check for fuel leaks by first applying soapy water to the area where the fuel suction plate sub-assembly and fuel pump gauge retainer contact, and then blow forcibly into the fuel inlet area through a flexible pouring spout or similar tube.
      GTY485950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Air
    2. Blow forcibly until the reverse flow prevention valve inside the fuel inlet activates.
      WARNING:

      Be careful not to inhale any fuel vapor.

      HINT: 

      There should be a faintly audible sound when the reverse flow prevention valve operates.

    3. If improper installation of the fuel suction tube with pump and gauge assembly, etc. has resulted in a condition where fuel will leak, air will leak out as shown in the illustration.
      GTY488200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Air Bubbles
      NOTE:

      If air leaks out, recheck the installation condition, and replace the used fuel pump gauge retainer and fuel suction tube set gasket with new ones. Also, make sure to fully wipe away the soapy water. (Any remaining soapy water can cause the fuel suction tube set gasket to slip and result in an improper seal.)

  5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [06/2015 - ]

  6. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  7. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.
    2. Clean the installation surfaces of the rear floor service hole cover and vehicle body.
    3. Connect the fuel pump connector.
    4. Install the rear floor service hole cover with new butyl tape.
  8. INSTALL NO. 1 QUARTER WHEEL HOUSE GUSSET SUB-ASSEMBLY 
    1. Install the No. 1 quarter wheel house gusset sub-assembly to the vehicle body with the 6 bolts.

      Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

    2. Return the front floor carpet assembly to its original position.
  9. INSTALL REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 7

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