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Fuel Pump ASSY: Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  PRECAUTION   ) 
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  3. DRAIN FUEL 
  4. REMOVE REAR SEAT CUSHION ASSY (See  OVERHAUL  ) 
  5. REMOVE REAR FLOOR SERVICE HOLE COVER NO. 2 
    1. Remove the 3 cap nuts and service hole cover.
    Fig 1: Removing Rear Floor Service Hole Cover No. 2
    G02958616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL PUMP TUBE SUB-ASSY 
    NOTE:
    • These procedures should be performed with the fuel tank less than 1/4 full.
    • Check for dirt and foreign matter 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.
    • Check for dirt and foreign matter on the pipe seal surface. Clean if necessary.
    • Put the pipe and connector ends in plastic bags to prevent damage and dirt and foreign matter.
    • If the pipe and connector are stuck together, pinch the tube and turn it carefully to free it. Then disconnect the tube.
    1. Remove the tube joint clip.
    2. Pull out the fuel pump tube.
    3. Plug the port of the fuel suction plate with a clean rubber cap.
      Fig 2: Removing Fuel Pump Tube Sub-Assy
      G02958617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and set plate.
  8. REMOVE FUEL PUMP AND SENDER GAUGE ASSY 
    1. Lift up the fuel pump and sender gauge, and disconnect the fuel sub-suction hose from the fuel return jet tube. Then remove the fuel pump, sender gauge and gasket.
      Fig 3: Disconnecting Fuel Sub-Suction Hose From Fuel Return Jet Tube
      G02958618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Be careful not to damage the fuel pump filter.
    • Be careful not to bend the sender gauge arm.
  9. 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.
    Fig 4: Removing Fuel Suction Support No. 2
    G02958619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL PUMP CUSHION RUBBER 
  11. 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.
    3. Remove the O-ring from the fuel pressure regulator.
      Fig 5: Removing Fuel Pressure W/Jet Pump Regulator Assy
      G02958620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. 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 assembly and suction plate.
    2. Disconnect the fuel pump connector.
    3. Remove the O-ring from the fuel port of the fuel suction plate.
      Fig 6: Removing Fuel Suction Plate W/Sender Gauge
      G02958621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL PUMP ASSY 
    1. Pull out the fuel pump with filter.
  14. INSTALL FUEL PUMP ASSY 
    1. Push in the fuel pump with filter.
  15. 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 Fuel Suction Plate W/Sender Gauge
      G02958622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. 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 rotate smoothly, the O-ring may be pinched. Remove the fuel pressure regulator and repeat steps ( b) and ( c) above.

    4. Connect the fuel return jet tube to the clamp of the fuel filter.
      Fig 8: Installing Fuel Pressure W/Jet Pump Regulator Assy
      G02958623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FUEL PUMP CUSHION RUBBER 
  18. INSTALL FUEL SUCTION SUPPORT NO. 2 
    1. Push the fuel suction support to the fuel filter and attach the 3 snap claws to the claw holes.
      Fig 9: Pushing Fuel Suction Support To Fuel Filter & Attach Snap Claws To Claw Holes
      G02958624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FUEL PUMP AND SENDER GAUGE ASSY 
    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 Pump & Sender Gauge Assy
      G02958625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the set plate with the 8 bolts.

      Torque: 6.0 N.m (61 kgf.cm, 52 in.lbf) 

  21. INSTALL FUEL PUMP TUBE SUB-ASSY 
    1. Attach the fuel tube connector to the fuel suction plate's port.
    2. Install the tube joint clip.
      Fig 11: Installing Fuel Pump Tube Sub-Assy
      G02958626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL REAR FLOOR SERVICE HOLE COVER NO. 2 
    1. Install the service hole cover with the 3 cap nuts.
      Fig 12: Installing Rear Floor Service Hole Cover No. 2
      G02958627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL REAR SEAT CUSHION ASSY (See  OVERHAUL  ) 
  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  25. PERFORM INITIALIZATION (See  INITIALIZATION  ) 
    NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  26. ADD FUEL 
  27. CHECK FOR FUEL LEAKS (See  PRECAUTION   ) 
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