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Fuel Pump: Replacement

CAUTION: Do not smoke or work near an open flame when working on the fuel pump.
  1. REMOVE LUGGAGE COMPARTMENT BOX (See  REMOVAL  ) 
  2. REMOVE FLOOR SERVICE HOLE COVER 
  3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 
  4. DISCONNECT VAPOR PRESSURE SENSOR CONNECTOR 
    1. Remove the 2 bolts and No. 3 fuel tank protector.
    2. Disconnect the sensor connector.
    Fig 1: Identifying Fuel Tank Protector Bolts
    G02630976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT FUEL TANK MAIN TUBE AND EMISSION TUBE 
    CAUTION:
    • Disconnect the fuel tube connector (quick type) observing the precaution (See SFI SYSTEM ).
    • As there is retained pressure in the fuel line, prevent if from splashing inside the luggage compartment.
    1. Remove the tube joint clip and disconnect the main tube.
    2. Disconnect the emission tube.
    Fig 2: Removing Tube Joint Clip
    G02630977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK 
    1. Remove the 6 bolts and fuel tank vent tube set plate.
    2. Remove the fuel pump and sender gauge assembly.
      NOTE:
      • Do not damage the fuel suction filter.
      • Be careful that the arm of the sender gauge is not bent.
    3. Remove the gasket from the pump and sender gauge assembly.
    Fig 3: Identifying Fuel Tank Vent Tube Set Plate Bolts
    G02630978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL SUCTION SUPPORT 
    1. Using a screwdriver, pry out the fuel suction support.
      NOTE: Be careful not to damage the suction support.
    2. Remove the rubber cushion.
    Fig 4: Removing Fuel Suction Support Using A Screwdriver
    G02630979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL SUCTION PLATE 
    1. Disconnect the fuel sender gauge connector and ground plate.
      Fig 5: Disconnecting Fuel Sender Gauge Connector And Ground Plate
      G02630980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers, pry out the fuel suction plate.
      NOTE: Be careful not to damage the suction support and suction plate.
      Fig 6: Prying Out Fuel Suction Plate Using Screwdrivers
      G02630981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the fuel pump harness.
    Fig 7: Removing Fuel Pump Harness
    G02630982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL PUMP 

    Pull out the fuel pump.

    Fig 8: Pulling Out Fuel Pump
    G02630983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL SUCTION FILTER FROM FUEL PUMP 
    1. Using a small screwdriver, pry out the clip.
    2. Pull out the suction filter.
    Fig 9: Removing Clip Using A Screwdriver
    G02630984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REINSTALL FUEL SUCTION FILTER 

    Install the suction filter with a new clip.

    Fig 10: Installing Suction Filter With A New Clip
    G02630985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REINSTALL FUEL PUMP 

    Push the fuel pump into fuel filter assembly.

    Fig 11: Pushing Fuel Pump Into Fuel Filter Assembly
    G02630986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REINSTALL FUEL SUCTION PLATE 
    1. Connect the fuel pump harness.
      Fig 12: Connecting Fuel Pump Harness
      G02630987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel suction plate to the fuel filter assembly.
      Fig 13: Installing Fuel Suction Plate To Fuel Filter Assembly
      G02630988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the fuel sender gauge connector and ground plate.
  14. REINSTALL FUEL SUCTION SUPPORT 
    1. Install the rubber cushion.
    2. Install the fuel suction support to the fuel filter assembly.
    Fig 14: Installing Fuel Suction Support To Fuel Filter Assembly
    G02630989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REINSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK 
    1. Install a new gasket to the fuel pump and sender gauge assembly.
    2. Insert the fuel pump assembly into the fuel tank.
      NOTE:
      • Do not damage the fuel suction filter.
      • Be careful that the arm of the sender gauge is not bent.
    3. Align the positioning mark of the set plate with the bolt hole position A.
    4. Install the fuel tank vent tube set plate with the 6 bolts.

      Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf) 

    Fig 15: Aligning Positioning Mark Of Set Plate With Bolt Hole Position A
    G02630990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. RECONNECT FUEL TANK MAIN TUBE AND EMISSION TUBE 
    1. Connect the main tube to fuel pump assembly with the tube joint clip.
    2. Connect the emission tube to the fuel pump assembly.
    Fig 16: Connecting Main Tube To Fuel Pump Assembly With Tube Joint Clip
    G02630991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Check that the connector is inserted fully and securely.
    • Check that the clip of the tube joint is on the collar of the connector.
    • After installing the clip of the tube joint, check that the connector is not pulled off.
    Fig 17: Installing Tube Joint Clip
    G02630992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. RECONNECT VAPOR PRESSURE SENSOR CONNECTOR 
    1. Connect the sensor connector.
    2. Install the No. 3 fuel tank protector with the 2 bolts.
  18. RECONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 
  19. CHECK FOR FUEL LEAKS (See  SFI SYSTEM  ) 
  20. REINSTALL FLOOR SERVICE HOLE COVER 
  21. REINSTALL LUGGAGE COMPARTMENT BOX (See  INSTALLATION  ) 
    Fig 18: Identifying Fuel Tank Protector Bolts
    G02630993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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