FUEL PUMP(for 2WD) 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 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 (w/ Simple Intelligent Parking Assist System)*1
		Pre-collision system
	Initialize back door lock	Power door lock control system	Click here
	Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)*2	Stop and start 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
*2: w/ Stop and start system

CAUTION:

Never perform work on fuel system components near any possible ignition sources.
Vaporized fuel could ignite, resulting in a serious accident.
Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

PROCEDURE

PRECAUTION

Note

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

Click here
DISCHARGE FUEL SYSTEM PRESSURE

Click here
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Click here

Note

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

Click here
REMOVE REAR SEAT ASSEMBLY

Click here
REMOVE CENTER REAR SEATBACK HINGE SUB-ASSEMBLY
1. w/ Seat Belt Warning System:
  1. Disconnect the 2 connectors.
  2. Disengage the clamp.
2. Remove the 2 bolts and center rear seatback hinge sub-assembly from the vehicle body.
REMOVE REAR FLOOR SERVICE HOLE COVER
1. *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. Disconnect the fuel suction tube with pump and gauge assembly connector.
DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY
1. Slide the clip and disconnect the No. 1 fuel evaporation tube sub-assembly from the fuel suction tube with pump and gauge assembly.
DISCONNECT CHARCOAL CANISTER OUTLET HOSE
1. Disconnect the charcoal canister outlet hose from the fuel suction tube with pump and gauge assembly.

DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Front Side of Vehicle

Disengage the 2 claws to remove the No. 1 fuel tube clamp.

*1	Fuel Suction Plate Sub-assembly
*2	Tube Joint Clip
*3	Fuel Tank Main Tube Sub-assembly
*4	Fuel Tube Joint
*5	O-ring
*a	Nylon Tube
	Pull off
	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 fuel suction plate sub-assembly are stuck, push and pull to release them.

REMOVE FUEL PUMP GAUGE RETAINER

Remove the fuel pump gauge retainer.

*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.

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

*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 )

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

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