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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. DRAIN FUEL (See  PRECAUTION  ) 
  3. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY LH (SEPARATED TYPE REAR SEAT) (See  OVERHAUL  ) 
  4. REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (FIXED TYPE REAR SEAT) (See  OVERHAUL  ) 
    Fig 1: Removing Service Hole Cover Nuts
    G01051867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE REAR FLOOR SERVICE HOLE COVER NO.2 
    1. Remove the 3 cap nuts and service hole cover.
  6. 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 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 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.
    Fig 2: Removing Fuel Tank Main Tube Sub-Assy
    G01051868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  7. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and fuel tank vent tube set plate.
  8. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY 
    1. Lift up the fuel pump and sender gauge assy. Disconnect the fuel sub-suction hose from the fuel return jet tube and remove the fuel pump, sender gauge assy and gasket.
    CAUTION:
    • Do not damage the fuel pump filter.
    • Be careful that the arm of the sender gauge should not bent.
    Fig 3: Disconnecting Fuel Sub-Suction Hose From Fuel Return Jet Tube
    G01051869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  10. REMOVE FUEL PUMP CUSHION RUBBER 
    Fig 4: Disconnecting 3 Snap Claws From Claw Holes Using 2 Screwdrivers
    G01051870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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, and remove the fuel pressure regulator and fuel return jet tube assy.
    3. Remove the O-ring from the fuel pressure regulator.
      Fig 5: Disconnecting Fuel Return Jet Tube From Clamp Of Fuel Filter
      G01051871Courtesy 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 assy.
      NOTE: Be careful not to damage the filter assy 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: Disconnecting 4 Snap Claws From Claw Holes
      G01051872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL PUMP FILTER 
    1. Remove the clip and fuel pump filter.
  14. REMOVE FUEL PUMP ASSY 
    1. Pull out the fuel pump assy.
    2. Remove the seal and spacer from the fuel pump assy.
  15. INSTALL FUEL PUMP ASSY 
    1. Apply some gasoline to a new seal.
    2. Install the spacer and a new seal to the fuel pump assy.
    3. Push in the fuel pump assy.
  16. INSTALL FUEL PUMP FILTER 
    1. Install the fuel pump filter with a new clip.
      Fig 7: Connecting Snap Claws To Claw Holes
      G01051873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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 assy, and attach the 4 snap claws to the claw holes.
  18. 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: Connecting Fuel Return Jet Tube To Clamp Of Fuel Filter
      G01051874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FUEL PUMP CUSHION RUBBER 
    Fig 9: Installing Fuel Pump Cushion Rubber
    G01051875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FUEL SUCTION SUPPORT NO.2 
    1. Push the fuel suction support, and attach the 3 snap claws to the claw holes.
    2. 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.
        Fig 10: Connecting Fuel Sub-Suction Hose To Fuel Return Jet Tube
        G01051876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach the fuel pump and sender gauge assy to the fuel tank.
  21. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the fuel tank vent tube set plate with the 8 bolts.

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

  22. 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
      G01051877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL REAR FLOOR SERVICE HOLE COVER NO.2 

    Install the service hole cover with the 3 cap nuts.

    Fig 12: Installing Service Hole Cover Cap Nuts
    G01051878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL BENCH TYPE REAR SEAT CUSHION ASSY (FIXED TYPE REAR SEAT) (See  OVERHAUL  ) 
  25. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY LH (SEPARATED TYPE REAR SEAT) (See  OVERHAUL  ) 
  26. ADD FUEL (See  PRECAUTION  ) 
  27. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  28. POWER WINDOW CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
  29. FRONT POWER SEAT CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
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