Fuel Pump: Replacement

CAUTION: Do not smoke or work near an open flame when working on the fuel pump.

REMOVE LH REAR SEAT
REMOVE FLOOR SERVICE HOLE COVER
DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
DISCONNECT VAPOR PRESSURE SENSOR CONNECTOR
DISCONNECT FUEL TANK MAIN 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 it from splashing inside the luggage compartment.
Remove the tube joint clip and disconnect the main tube.

Fig 1: Removing Tube Joint Clip & Disconnecting Main Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK
1. Remove the 8 bolts and fuel tank vent tube set plate.
  
  Fig 2: Removing Bolts & Fuel Tank Vent Tube Set Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Lift up the fuel pump and sender gauge assembly, and disconnect the fuel sub suction hose from the fuel return jet tube. Remove the fuel pump, sender gauge assembly and gasket.
  
  Fig 3: Disconnecting Fuel Sub Suction Hose From Fuel Return Jet Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not damage the fuel suction filter.
  - Be careful not to bend the arm of the sender gauge.
3. Remove the gasket from the suction plate.
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: Prying Out Fuel Suction Support Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SUCTION PLATE
1. Disconnect the fuel sender gauge connector and ground plate.
  
  Fig 5: Disconnecting Fuel Sender Gauge Connector And Ground Plate
  Courtesy 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 Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the fuel pump harness.
  
  Fig 7: Removing Fuel Pump Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SUCTION FILTER FROM FUEL PUMP
1. Using a small screwdriver, pry out the clip.
2. Pull out the suction filter.
  
  Fig 9: Prying Out Clip Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REINSTALL FUEL SUCTION FILTER
Install the suction filter with a new clip.

Fig 10: Installing Suction Filter With Clip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REINSTALL FUEL PUMP
Push into the fuel pump.

Fig 11: Pushing In Fuel Pump
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REINSTALL FUEL SUCTION PLATE
1. Connect the fuel pump harness.
  
  Fig 12: Connecting Fuel Pump Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the fuel suction plate and fuel filter assembly.
  
  Fig 13: Installing Fuel Suction Plate And Fuel Filter Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the fuel sender gauge connector and ground plate.
  
  Fig 14: Connecting Fuel Sender Gauge Connector And Ground Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION SUPPORT
1. Install the rubber cushion.
2. Install the fuel suction support to the fuel filter assembly.
  
  Fig 15: Installing Fuel Suction Support To Fuel Filter Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REINSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK
1. Install a new gasket to the suction plate.
2. Connect the sub suction hose to the fuel return jet tube.
  
  Fig 16: Connecting Sub Suction Hose To Fuel Return Jet Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert the fuel pump assembly into the fuel tank.
  NOTE:
  - Do not damage the fuel suction filter.
  - Be careful not to bend the arm of the sender gauge.
4. Align the positioning mark of the set plate with bolt hole position A.
5. Install the fuel tank vent tube set plate with the 8 bolts.
  Torque: 4.0 N.m (40 kgf.cm, 35 in.lbf)
  
  Fig 17: Installing Fuel Tank Vent Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
RECONNECT FUEL TANK MAIN TUBE
Connect the main tube with the tube joint clip.

Fig 18: Connecting Main Tube With Tube Joint Clip
Courtesy 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 19: Identifying Fuel Tube Joint, Fuel Suction Plate, Fuel Pump Tube, Clip & O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
RECONNECT VAPOR PRESSURE SENSOR CONNECTOR
RECONNECT FUEL PUMP and SENDER GAUGE CONNECTOR
CHECK FOR FUEL LEAK (See SFI SYSTEM )
REINSTALL FLOOR SERVICE HOLE COVER
REINSTALL LH REAR SEAT