FUEL PUMP REMOVAL

Info Added 2017-10-06

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel pump removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Disconnect cable from negative auxiliary battery terminal Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Simple intelligent parking assist system*1
Toyota parking assist-sensor system*1
Pre-collision system
Initialize back door lock Power door lock control system

Click here

Replacement of fuel pump Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

Click here

*1: When performing learning using the GTS.

Click here

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  4. REMOVE REAR SEAT ASSEMBLY

    Click here

  5. REMOVE REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH

    Click here

  6. REMOVE REAR SEAT INNER BELT ASSEMBLY

    Click here

  7. REMOVE CENTER REAR SEATBACK HINGE SUB-ASSEMBLY


    1. A001RZF

      Remove the 2 bolts and center rear seatback hinge sub-assembly from the vehicle body.

  8. REMOVE NO. 8 WIRING HARNESS PROTECTOR


    1. Remove the No. 8 wiring harness protector from the rear floor service hole cover.

  9. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A001RIVC01
      *a Protective Tape

      Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.

    2. A001QEC

      Disconnect the fuel pump connector.

  10. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY


    1. A001QPC

      Disconnect the fuel tank vent hose sub-assembly from the fuel suction tube with pump and gauge assembly.

      Click here

  11. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A001OSVC01
      *1 Plate Sub-assembly
      *2 Tube Joint Clip
      *3 Fuel Tank Main Tube Sub-assembly
      *4 Fuel Tube Joint
      *5 O-ring
      *a Nylon Tube
      B0048I2 Pull off
      B0048S8 Pull off

      Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

      Note


      • Remove any foreign matter on the fuel tube joint before performing this work.

      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

      • Be sure to disconnect the fuel tube joint by hand.

      • Do not bend, twist, pinch or kink the nylon tube.

      • Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.

      • If the fuel tube joint and plate sub-assembly are stuck, push and pull to release them.

  12. REMOVE FUEL PUMP GAUGE RETAINER


    1. A001PQEC01
      B0048I2 Front Side

      Disengage the claw to remove the No. 1 fuel tube clamp.

    2. Remove the fuel pump gauge retainer.


      1. A001QHZC01
        *a Insertion Point
        *b SST (Plate)
        *c SST (Claw)
        *d SST (Bolt)

        Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

        SST
        09808-01071
        09808-14031   ( 09808-01030, 09808-01090 )

        Tech Tips

        Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

      2. While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

      3. A001PDZC01
        *a SST (Handle)
        *b SST (Plate)
        *c SST (Claw)
        *d SST (Bolt)

        Install SST (handle) to SST (plate).

        SST
        09808-01071
        09808-14031   ( 09808-01010, 09808-01030, 09808-01090 )

      4. Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

        Note


        • Do not use any tools other than specified in this operation as this may result in damage to the fuel pump gauge retainer or the fuel tank assembly.

        • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.

        • Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.

        • Do not spin SST too fast or use an impact wrench as this may result in damage to components.

        • If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.

      5. While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.

  13. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.

      Note

      Be careful not to bend the arm of the fuel sender gauge assembly.

    2. A001PWP

      Remove the fuel suction tube set gasket from the fuel tank assembly.