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Fuel Pump: Removal

CAUTION: Do not smoke or work near an open flame when working on the fuel pump.
  1. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL   ) 
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  3. REMOVE REAR NO. 1 SEAT 
    1. Remove the 2 seats.
  4. REMOVE REAR DOOR SCUFF PLATE 
  5. REMOVE STEP PLATE 
  6. REMOVE REAR SEAT LOCK COVER 
  7. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Take off the front and rear floor carpets.
    2. Remove the 2 screws and floor service hole cover.
  8. DISCONNECT FUEL MAIN TUBE AND RETURN TUBE 
    CAUTION:
    • Prevent the retained pressure in the fuel line from splashing inside the vehicle compartment.
    • When sealing the tube and suction plates with the O-ring of the quick connector, be careful not to damage any contact surfaces or allow foreign matter to contact any surface.
    • Be sure to perform the disconnection by hand. Do not use tools.
    • Do not bend or turn the nylon tube by force.
    1. Before the operation, remove foreign matter or dirt sticking to the tube joint clips.
      Fig 1: Removing Foreign Matter Or Dirt Sticking To Tube Joint Clips
      G04436033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Widen the tip of the clips with your fingers and pull them out for disconnection.
    3. Pull out the fuel main tube and the return tube.

      If the nylon tube and the suction plate stick together, turn the nylon tube with your fingers and pull it out for disconnection.

      NOTE: Plug the port and the fuel suction plate with a clean rubber cap.
      Fig 2: Pulling Out Fuel Main Tube & Return Tube
      G04436034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. After the disconnection, protect the connector with a plastic bag.
  9. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY 
    1. Remove the 8 bolts.
    2. Pull out the fuel pump and sender gauge assembly.
      NOTE:
      • Do not damage the fuel pump filter.
      • Be careful that the arm of the sender gauge is not bent.
    3. Remove the gasket from the fuel suction plate.
      Fig 3: Removing Fuel Pump & Sender Gauge Assembly
      G04436035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE LEAD WIRE 
    1. Remove the lead wire from the fuel pump.
  11. REMOVE FUEL PUMP 
    1. Pull out the lower side of the fuel pump from the pump bracket.
      Fig 4: Pulling Out Lower Side Of Fuel Pump From Pump Bracket
      G04436036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel hose from the fuel pump, and remove the fuel pump.
    3. Remove the rubber cushion from the fuel pump.
    4. Using a screwdriver, detach the 4 claws from the claw holes and disconnect the fuel pump and fuel pump filter assembly.

      HINT:

      Tape the screwdriver tip before use.

      Fig 5: Disconnecting Fuel Pump & Fuel Pump Filter Assembly
      G04436037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the O-ring from the fuel pump.
      Fig 6: Removing O-Ring From Fuel Pump
      G04436038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL PUMP FILTER 
    1. Remove the fuel pump filter from the fuel pump.
      Fig 7: Removing Fuel Pump Filter From Fuel Pump
      G04436039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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