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Fuel Pump: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    (See PRECAUTION  )

  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 Fuel Pump Connector, Clamp And Vapor Pressure Sensor Connector
      G05859059Courtesy 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: Removing 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 Bolts
      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.
    6. Remove the gasket from the fuel suction tube.
      Fig 4: Identifying Fuel Pump Assembly
      G05200865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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
      G05200866Courtesy 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: Removing Fuel Suction Plate Sub-Assembly
      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 And 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: Disengaging Snap Claws From Claw Holes
      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: Identifying Fuel Pump And Fuel Filter Assembly
      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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