Fuel Pump: Disassembly

REMOVE FUEL TANK TO FILLER PIPE HOSE (See REMOVAL )
REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Remove the tube joint clip, and pull out the fuel main tube.
  NOTE:
  - Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary
  - Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
  - Do not use any tool in this operation.
  - Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
  - When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
    
    Fig 1: Locating Fuel Tank Main Tube Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Unfasten the 4 claws and remove the fuel tank main tube from the fuel tank.
  
  Fig 2: Locating Fuel Tank Main Tube And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
1. Using SST, loosen the fuel pump gauge retainer.
  SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
  
  HINT:
  
  A rib on the fuel pump gauge retainer can be fitted into a tip of SST.
2. Remove the fuel pump gauge retainer.
3. Remove the fuel suction tube assembly with pump and gauge and the fuel suction tube set gasket from the fuel tank.
  
  Fig 3: Removing Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not bend the arm of the fuel sender gauge.
REMOVE FUEL SENDER GAUGE ASSEMBLY
1. Disconnect the fuel sender gauge connector.
2. Unlock the fuel sender gauge and slide it to remove.
  
  Fig 4: Disconnecting Fuel Sender Gage Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
1. Using a screwdriver with the tip wrapped in tape, disconnect the 4 snap-claws from the claw holes and remove the fuel suction plate.
  NOTE: Do not damage the fuel suction plate and the No. 1 fuel suction support.
  
  Fig 5: Identifying Fuel Suction Plate Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP
1. Disconnect the fuel pump connector.
2. Using a small screwdriver with the tip wrapped in tape, disconnect the 2 claws from the claw holes and pull out the fuel pump.
  NOTE: Do not damage the fuel pump and the fuel suction plate.
3. Remove the O-ring and the fuel pump spacer from the fuel pump.
  
  Fig 6: Removing O-Ring And Fuel Pump Spacer From Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL FILTER ASSEMBLY
1. Using a small screwdriver, pry out the clip.
2. Remove the fuel filter assembly from the fuel pump.
  
  Fig 7: Removing Fuel Filter And Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 FUEL TUBE JOINT
1. Remove the connector.
2. Using a screwdriver with the tip wrapped in tape, disconnect the snap-claw from the claw hole and pull out the No. 1 fuel tube joint.
  NOTE: Do not damage the No. 1 fuel tube joint and the fuel suction plate.
  
  Fig 8: Removing Fuel Tube Joint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP HARNESS
1. Remove the fuel pump harness from the No. 1 fuel tube joint.
  
  Fig 9: Removing Fuel Pump Harness From Fuel Tube Joint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
1. Remove the clip.
2. Pull out the fuel pressure regulator from the fuel suction plate.
3. Remove the 2 O-rings from the fuel pressure regulator.
  
  Fig 10: Removing O-Rings From Fuel Pressure Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002