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Fuel Pump ASSY: Replacement

  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT 
  2. DRAIN FUEL 
  3. REMOVE REAR SEAT CUSHION ASSEMBLY 
  4. REMOVE REAR FLOOR SERVICE HOLE COVER NO.2 
  5. REMOVE FUEL PUMP TUBE SUB-ASSY 
    NOTE:
    • Operation should be done under the condition that the remaining fuel is less than 1/4 in the tank. 
    • Check if there is any dirt like mud around the connector before this work and clean the dirt away. 
    • Be careful of dirt like mud because the quick connector has an O-ring to seal the pipe and the connector. 
    • Do not use any tool in this work. 
    • Do not bend or twist the nylon tube by force. 
    • After disconnecting the tube, cover the connector with a vinyl bag. 
    • When the connector and the pipe are stuck, pinch the tube between fingers, and turn it carefully to free and 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 1: Removing Fuel Pump Tube Sub-Assy
      G00935554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and fuel tank vent tube set plate.
  7. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY 
    1. Lift up the fuel pump and sender gauge assembly, and disconnect the fuel sub-suction hose from the fuel return jet tube and remove the fuel pump, sender gauge assembly and gasket.
      CAUTION:
      • Do not damage the fuel pump filter. 
      • Be careful that the arm of the sender gauge should not bent. 
        Fig 2: Identifying Fuel Pump Sub-Section Hose
        G00935555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL SUCTION SUPPORT NO. 2 
  9. REMOVE FUEL PUMP CUSHION RUBBER 
  10. REMOVE FUEL PRESSURE W/JET PUMP REGULATOR ASSY 
  11. 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 assembly.
      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 3: Disconnecting Snap Claws From Claw Holes & Removing Fuel Filter Assembly
      G00935556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL PUMP FILTER 
  13. REMOVE FUEL PUMP ASSY 
    1. Pull out the fuel pump assembly with filter.
  14. INSTALL FUEL PUMP ASSY 
    1. Apply some gasoline to the O-ring.
    2. Push in the fuel pump assembly with filter.
  15. INSTALL FUEL PUMP FILTER 
    1. Install the fuel pump filter with a new clip.
  16. 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 assembly, and attach the 4 snap claws to the claw holes.
      Fig 4: Identifying Snap Claw
      G00935557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FUEL PRESSURE W/JET PUMP REGULATOR ASSY 
    1. Apply some gasoline to a new O-ring, and install the fuel pressure with jet pump regulator assembly to the fuel filter of the fuel tank.
  18. INSTALL FUEL PUMP CUSHION RUBBER 
  19. INSTALL FUEL SUCTION SUPPORT NO.2 
  20. 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 assembly to the fuel tank.
      Fig 5: Installing Fuel Pump & Sender Gauge Assembly
      G00935558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 PUMP TUBE SUB-ASSY 
    1. Attach the fuel tube connector to the port of the fuel suction plate.
    2. Install the tube joint clip.
      Fig 6: Attaching Fuel Tube Connector To Port Of Fuel Suction Plate
      G00935559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL REAR FLOOR SERVICE HOLE COVER NO.2 
  24. INSTALL REAR SEAT CUSHION ASSEMBLY 
  25. ADD FUEL 
  26. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS 
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