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Fuel Pump: Removal

CAUTION: Do not smoke or work near an open frame when working the fuel pump. 
  1. REMOVE NO.1 REAR SEATS 
  2. REMOVE REAR DOOR SCUFF PLATES, STEP PLATES AND REAR SEAT LOCK COVERS 
  3. REMOVE FLOOR SERVICE HOLE COVER 
    1. Take off the front and rear floor carpels.
    2. Remove the 2 Screws and service hole cover.
  4. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 
  5. DISCONNECT FUEL MAIN TUBE AND RETURN TUBE (FUEL TUBE CONNECTORS) FROM FUEL SUCTION PLATE 
    CAUTION:
    • Perform disconnecting operation of the fuel tube connector (quick type) after reading the precautions. (See  PRECAUTION  ) 
    • Prevent the retained pressure in the fuel line from splashing inside the vehicle compartment. 
    • Be careful not to damage the contact surface or let the foreign matters on there when sealing the tube and the suction plates with the quick connectors through O-ring. 
    • Be sure to perform the disconnection by hand. Do not use tools. 
    • Do not bend or turn the nylon tube by force. 
    1. Before the operation, remove foreign matters or dirt sticking to the tube joint clips.
    2. Enlarge the tip of the clips with fingers and pull them out for disconnection.
      Fig 1: Identifying Tube Joint Clip
      G00920303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pull out the fuel main tube and the return tube.

      If the nylon tube and the suction plate stick together, ease the connection by turning the nylon tube with fingers and pull it out for disconnection.

      Fig 2: Identifying Tube
      G00920304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Plug the port of the fuel suction plate with a clean rubber cap. 
    4. After the disconnection, protect the connector with a plastic bag.
  6. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK 
    1. Remove the 8 bolts.
    2. Pull out the fuel pump and the sender gauge assembly.
      NOTE:
      • Do not damage the fuel pump filter. 
      • Be careful that the arm of the sender gauge should not bent. 
    3. Remove the gasket from the fuel section plate. 
    Fig 3: Removing Bolts & Fuel Pump & Sender Gauge Assembly
    G00920305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE LEAD WIRE FROM FUEL PUMP 
  8. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET 
    1. Pull out the lower side of the fuel pump from the pump bracket.
    2. Disconnect the fuel hose from the fuel pump, and remove the fuel pump.
    3. Remove the rubber cushion from the fuel pump.
    Fig 4: Disconnecting Fuel Hose From Fuel Pump
    G00920306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL PUMP FILTER FROM FUEL PUMP 
    1. Using a small screwdriver, remove the clip.
    2. Pull out the pump filter.
    Fig 5: Removing Pump Filter
    G00920307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002


  1. REMOVE V-BANK COVER 
  2. REMOVE FUEL PRESSURE REGULATOR 
    1. Disconnect these hoses from the pressure regulator:
      • Vacuum sensing hose from intake air resonator
      • Fuel return hose
      CAUTION: Put a shop rag under the pressure regulator. 
      Fig 1: Identifying Hoses
      G00920308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, and pull out the pressure regulator.
    3. Remove the O-ring from the pressure regulator.
    Fig 2: Removing Pressure Regulator
    G00920309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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