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Fuel Pump ASSY: Replacement

CAUTION: Do not smoke or work near an open frame when working on the fuel pump.
  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  PRECAUTION   ) 
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 
  3. DRAIN FUEL (See  PRECAUTION   ) 
  4. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY LH (SEPARATED TYPE REAR SEAT) (See  OVERHAUL  ) 
  5. REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (FIXED TYPE REAR SEAT) (See  OVERHAUL  ) 
  6. REMOVE REAR FLOOR SERVICE HOLE COVER NO.2 
    1. Remove the 3 cap nuts and service hole cover.
  7. REMOVE FUEL TANK MAIN TUBE SUB-ASSY 
    NOTE:
    • These procedures should be performed with the fuel tank less than 1/4 full.
    • Check for dirt contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
    • Do not use any tools in these procedures.
    • Do not forcefully bend or twist the nylon tube.
      Fig 1: Identifying Service Hole Cover
      G02998991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Check for dirt contamination on the pipe seal surface. Clean if necessary.
    • Put the pipe and connector ends in vinyl bags to prevent damage and dirt contamination.
    • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
    1. Remove the tube joint clip.
    2. Pull out the fuel main tube.
    3. Plug the port of the fuel suction plate with a clean rubber cap.
    Fig 2: Pulling Out Fuel Main Tube
    G02998992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and set plate.
  9. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY 
    1. Lift up the fuel pump and sender gauge. Disconnect the fuel sub-suction hose from the fuel return jet tube and remove the fuel pump, sender gauge and gasket.
    CAUTION:
    • Do not damage the fuel pump filter.
    • Be careful not to bend the arm of the sender gauge.
    Fig 3: Disconnecting Fuel Sub-Suction Hose
    G02998993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL SUCTION SUPPORT NO.2 
    1. Using 2 screwdrivers, disconnect the 3 snap claws from the claw holes and remove the fuel suction support.
    NOTE: Be careful not to damage the suction support and fuel filter.
  11. REMOVE FUEL PUMP CUSHION RUBBER 
    Fig 4: Disconnecting Snap Claws From Claw Holes
    G02998994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL PRESSURE W/JET PUMP REGULATOR ASSY 
    1. Disconnect the fuel return jet tube from the clamp of the fuel filter.
    2. Pull out the fuel pressure regulator from the fuel filter, and remove the fuel pressure regulator and fuel return jet tube.
    3. Remove the O-ring from the fuel pressure regulator.
    Fig 5: Disconnecting Fuel Return Jet Tube From Clamp Of Fuel Filter
    G02998995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL SUCTION PLATE W/SENDER GAUGE 
    1. Using 2 screwdrivers, disconnect the 4 snap claws from the claw holes and remove the fuel filter.
      NOTE: Be careful not to damage the filter assy and suction plate.
      Fig 6: Disconnecting Snap Claws From Claw Holes
      G02998996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pump connector.
    3. Remove the O-ring from the fuel port of the fuel suction plate.
  14. REMOVE FUEL PUMP FILTER 
    1. Remove the clip and filter.
  15. REMOVE FUEL PUMP ASSY 
    1. Pull out the fuel pump.
    2. Remove the seal and spacer from the fuel pump.
  16. INSTALL FUEL PUMP ASSY 
    1. Apply some gasoline to a new seal.
    2. Install the spacer and a new seal to the fuel pump.
    3. Push in the fuel pump.
  17. INSTALL FUEL PUMP FILTER 
    1. Install the filter with a new clip.
  18. INSTALL FUEL SUCTION PLATE W/SENDER GAUGE 
    1. Apply a light coat of gasoline to a new O-ring, and install it to the fuel port of the fuel suction plate.
    2. Connect the fuel pump connector.
    3. Push the fuel filter, and attach the 4 snap claws to the claw holes.
    Fig 7: Installing Snap Claws To Claw Holes
    G02998997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FUEL PRESSURE W/JET PUMP REGULATOR ASSY 
    1. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
    2. Push in the fuel pressure regulator to the fuel filter.
    3. Check that the fuel pressure regulator rotates smoothly.

      If it does not rotates smoothly, the O-ring may be pinched. Remove the fuel pressure regulator and perform steps ( b) and ( c) above.

    4. Connect the fuel return jet tube to the clamp of the fuel filter.
    Fig 8: Installing Fuel Pressure Regulator
    G02998998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FUEL PUMP CUSHION RUBBER 
  21. INSTALL FUEL SUCTION SUPPORT NO.2 
    1. Push the fuel suction support, and attach the 3 snap claws to the claw holes.
    Fig 9: Pushing Fuel Suction Support
    G02998999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY 
    1. Install a new gasket to the fuel suction plate.
    2. Connect the fuel sub-suction hose to the fuel return jet tube.
    3. Attach the fuel pump and sender gauge to the fuel tank.
    Fig 10: Installing Fuel Sub-Suction Hose
    G02999000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the set plate with the 8 bolts.
    1. Torque: 6.0 N.m (61 kgf.cm, 52 in..lbf) 
  24. INSTALL FUEL TANK MAIN TUBE SUB-ASSY 
    1. Attach the fuel tube connector to the port of the fuel suction plate.
    2. Install the tube joint clip.
    Fig 11: Installing Fuel Tube Connector
    G02999001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL REAR FLOOR SERVICE HOLE COVER NO.2 

    Install the service hole cover with the 3 cap nuts.

    Fig 12: Installing Service Hole Cover
    G02999002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL BENCH TYPE REAR SEAT CUSHION ASSY (FIXED TYPE REAR SEAT) (See  OVERHAUL  ) 
  27. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY LH (SEPARATED TYPE REAR SEAT) (See  OVERHAUL  ) 
  28. ADD FUEL (See  PRECAUTION   ) 
  29. CONNECT BATTERY NEGATIVE TERMINAL 
    NOTE: When disconnecting the negative (-) battery terminal, initialize the following system(s) after the terminal is reconnected (see INITIALIZATION ).
  30. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION   ) 
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