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Fuel Pump: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    (See FUEL SYSTEM )

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE EXHAUST PIPE ASSEMBLY CENTER 

    (See REMOVAL )

  4. REMOVE FRONT FLOOR HEAT INSULATOR NO.3 (See  REMOVAL  ) 
  5. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1 (See  REMOVAL  ) 
  6. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.3 (See  REMOVAL  ) 
  7. DISCONNECT FUEL TANK WIRE (See  REMOVAL  ) 
  8. REMOVE CHARCOAL CANISTER PROTECTOR (See  REMOVAL  ) 
  9. DISCONNECT CHARCOAL CANISTER FUEL HOSE (See  REMOVAL  ) 
  10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (See  REMOVAL  ) 
  11. DISCONNECT BREATHER LOWER TUBE (See  REMOVAL  ) 
  12. REMOVE FUEL TANK ASSEMBLY (See  REMOVAL  ) 
  13. REMOVE FUEL PUMP AND GAUGE WITH SUCTION TUBE 
    1. Disconnect the fuel pump connector.
    2. Disconnect the clamp and vapor pressure sensor connector.
      Fig 1: Locating Vapor Pressure Sensor Connector And Clamp
      G05200862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the tube joint clip and clamp, and pull out the fuel pump tube.
      NOTE:
      • Check that there is no dirt or foreign matter around the fuel tube joint and after cleaning off any excess dirt, proceed with the work.
      • Be careful not to allow dirt or foreign matter to scratch or come into contact with the fuel tube connector and fuel suction plate that are sealed by O-rings.
      • Do not use any tools for this work.
      • Do not bend, kink or twist the nylon tube by force.
      • Cover the disconnected fuel tube joint with a plastic bag.
      • When the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube with the fingers, and turn it carefully to release. Disconnect the fuel tank tube.
      Fig 2: Locating Tube Joint Clip And Clamp
      G05200903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 8 bolts, fuel tank vent tube set plate and fuel pump connector plate.
      Fig 3: Locating Fuel Tank Vent Tube Set Plate And Fuel Pump Connector Plate
      G05200864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Pull out the fuel pump assembly from the fuel tank.
      NOTE:
      • Do not damage the fuel pump filter.
      • Be careful not to bend the arm of the sender gauge.
        • Fig 4: Identifying Out Fuel Pump Assembly
        G05200865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the gasket from the fuel suction tube.
  14. REMOVE VAPOR PRESSURE SENSOR ASSEMBLY 
    1. Remove the cover.
    2. Remove the tube joint clip, and pull out the vapor pressure sensor.
    Fig 5: Identifying Tube Joint Clip And Cover
    G05276415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Disconnect the fuel sender gauge connector.
    2. Unlock the fuel sender gauge, then slide and remove it.
    Fig 6: Removing Fuel Sender Gauge Assembly
    G05200867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY 
    1. Disconnect the fuel pump connector.
    2. Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws from the claw holes, and pull out the fuel suction plate.
    NOTE: Do not damage the fuel suction support.
    Fig 7: Locating Fuel Suction Plate
    G05200868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL PUMP HARNESS 
    1. Disconnect the connector.
    2. Using a screwdriver, pry out the fuel pump harness.
    Fig 8: Locating Fuel Pump Harness With Connector
    G05200869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL SUCTION SUPPORT NO.2 
    1. Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws from the claw holes, and remove the fuel suction support.
    NOTE: Do not damage the fuel suction support.
    Fig 9: Locating Fuel Suction Support No.2
    G05200870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FUEL PUMP CUSHION RUBBER 
    1. Remove the fuel pump cushion rubber from the fuel pump.
    Fig 10: Identifying Fuel Pump Cushion Rubber
    G05200871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FUEL PUMP AND FUEL FILTER ASSEMBLY 
    1. Pull out the fuel pump from the fuel tank fuel filter.
    Fig 11: Pulling Out Fuel Pump From Fuel Tank Fuel Filter
    G05200872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FUEL PRESSURE WITH JET PUMP REGULATOR ASSEMBLY 
  1. Remove the fuel pressure with jet pump regulator assembly from the fuel tank fuel filter.
    Fig 12: Identifying Fuel Pressure With Jet Pump Regulator Assembly
    G05200873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the O-ring from the fuel pressure with jet pump regulator assembly.
Fig 13: Identifying O-Ring
G05200874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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