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Home >> Toyota >> 2004 >> Matrix Base, 4WD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Engine Fuel System >> Fuel Pump ASSY (4WD) >> Components >> Removal & Installation
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Removal & Installation

  1. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY 
    1. Remove the 2 installing bolts of the rear seat cushion.
    Fig 1: Removing 2 Installing Bolts Of Rear Seat Cushion
    G00922784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear service hole cover.
      Fig 2: Removing Rear Service Hole Cover
      G00922785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pump and vapor pressure sensor connector.
    Fig 3: Disconnecting Fuel Pump & Vapor Pressure Sensor Connector
    G00922786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT 
    1. Start the engine.
    2. After the engine has stopped on the its own, turn the ignition switch to lock.
  4. REMOVE FUEL TANK PROTECTOR No. 2 
    Fig 4: Identifying Fuel Tank Protector No. 2
    G00922787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolts and fuel tank protector.
  5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    1. Remove the tube joint clip, and pull out the fuel tank main tube.
    Fig 5: Removing Tube Joint Clip
    G00922788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Check if there is any dirt like mud around the fuel tube joint before this work and clean dirt away.
    • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube joint and fuel suction plate.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube joint with a vinyl bag.
    • When the fuel tube joint and plug are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.
      Fig 6: Disconnecting Fuel Tube Joint
      G00922789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL TANK VENT TUBE SET PLATE 
    Fig 7: Identifying Fuel Tank Vent Tube Set Plate
    G00922790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 5 bolts and fuel tank vent tube set plate.
  7. REMOVE FUEL PUMP ASSEMBLY 
    Fig 8: Removing Fuel Pump Assembly
    G00922791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pull out the fuel pump assembly.
    NOTE:
    • Do not damage the fuel pump filter.
    • Be careful that the arm of the fuel sender gauge should not bent.
  8. REMOVE FUEL SUCTION TUBE SET GASKET 
    1. Remove the gasket from the fuel pump assembly.
    Fig 9: Removing Gasket From Fuel Pump Assembly
    G00922792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL SUCTION SUPPORT No. 2 
    1. Using a screwdriver, disconnect the 5 snap claws from the claw holes, and remove the fuel suction support.
      Fig 10: Disconnecting Snap Claws Using Screwdriver
      G00922793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not damage the fuel suction support.
  10. REMOVE FUEL PUMP CUSHION RUBBER 
    1. Remove the fuel pump cushion rubber.
    Fig 11: Removing Fuel Pump Cushion Rubber
    G00922794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL SENDER GAGE ASSY 
    1. Disconnect the fuel sender gage connector.
    2. Using a screwdriver, unlock the fuel sender gage, and slide it remove.
    Fig 12: Unlocking Fuel Sender Gage Using Screwdriver
    G00922795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL SUCTION PLATE SUB-ASSY 
    1. Disconnect the fuel pump connector.
    2. Using a screwdriver, disconnect the 4 snap claws from the claw holes, and pull out the fuel suction plate.
      Fig 13: Disconnecting Snap Claws Using Screwdriver
      G00922796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not damage the fuel suction plate.
  13. REMOVE VAPOR PRESSURE SENSOR ASSY 
    Fig 14: Removing Vapor Pressure Sensor Assy
    G00922797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the tube joint clip, and pull out the vapor pressure sensor.
  14. REMOVE FUEL PUMP HARNESS 
    1. Remove the fuel pump harness from the fuel suction plate.
    Fig 15: Removing Fuel Pump Harness From Fuel Suction Plate
    G00922798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL PUMP 
    Fig 16: Removing Fuel Pump
    G00922799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pull out the fuel pump from the fuel filter.
  16. REMOVE FUEL PUMP FILTER 
    Fig 17: Removing Fuel Pump Filter
    G00922800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a small screwdriver, pry out the clip.
    2. Pull out the fuel pump filter from the fuel pump.
  17. REMOVE FUEL PRESSURE REGULATOR ASSY 
    Fig 18: Removing Fuel Pressure Regulator Assy
    G00922801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pull out the fuel pressure regulator from the fuel filter.
  18. REMOVE FUEL PRESSURE REGULATOR O-RING 
    Fig 19: Removing Fuel Pressure Regulator O-Ring
    G00922802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove an O-ring from the fuel pressure regulator.
  19. INSTALL FUEL PRESSURE REGULATOR O-RING 
    Fig 20: Installing Fuel Pressure Regulator O-Ring
    G00922803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
  20. INSTALL FUEL PUMP FILTER 
    1. Install the fuel pump filter with a new clip.
  21. INSTALL FUEL PUMP 
    1. Apply a light coat of gasoline to an O-ring, and install the fuel pump to the fuel filter.
    Fig 21: Applying Light Coat Of Gasoline To An O-Ring
    G00922804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL VAPOR PRESSURE SENSOR ASSY 
    1. Install the vapor pressure sensor with the tube joint clip.
    NOTE:
    • Check that there is no scratch or foreign objects on the connecting parts.
    • Check that the fuel tube joint is inserted fully and securely.
    • Check that the tube joint clip is on the collar of the fuel tube joint.
    • After installing the tube joint clip, check that the fuel tube joint is not pulled off.
  23. INSTALL FUEL SUCTION TUBE SET GASKET 
    1. Install a new gasket to the fuel pump assembly.
  24. INSTALL FUEL PUMP ASSEMBLY 
    1. Install the fuel pump assembly to the fuel tank.
    NOTE:
    • Do not damage the fuel pump filter.
    • Be careful that the arm of the fuel sender gauge should not bent.
  25. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the fuel tank vent tube set plate with the 5 bolts.
      1. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 
  26. CONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    1. Install the fuel tank main tube with the tube joint clip.
    NOTE:
    • Check that there is no scratch or foreign objects on the connecting parts.
    • Check that the fuel tube joint is inserted fully and securely.
    • Check that the tube joint clip is on the collar of the fuel tube joint.
    • After installing the tube joint clip, check that the fuel tube joint is not pulled off.
  27. INSTALL FUEL TANK PROTECTOR No. 2 
    1. Install the fuel tank protector with the 3 bolts.
      1. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 
  28. CHECK FUEL LEAK (See  FUEL SYSTEM   ) 
  29. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Using the butyl tape, install the rear floor service hole cover.
    Fig 22: Installing Rear Floor Service Hole Cover Using Butyl Tape
    G00922805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY 
    1. Install the rear seat cushion with the 2 bolts.
      1. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) 
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