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Fuel Pump ASSY: Replacement

WARNING: This page is about a different car, the 2004 Toyota Camry. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE (See  PRECAUTION  ) 
  2. REMOVE REAR SEAT CUSHION ASSEMBLY (See  OVERHAUL  ) 
  3. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear floor service hole cover.
    2. Disconnect the vapor pressure sensor connector.
    3. Disconnect the fuel pump connector.
      Fig 1: Removing Rear Floor Service Hole Cover
      G02624494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. SEPARATE FUEL PUMP TUBE SUB-ASSY 
    1. Remove the tube joint clip, and pull out the fuel pump tube.
      Fig 2: Removing Tube Joint Clip
      G02624495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Before this operation, check the connector for dirt, mud or other contamination.
    • Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
    • Do not use any tools 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 the connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe.
      Fig 3: Identifying Fuel Tube Joint
      G02624496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and the set plate.
      Fig 4: Removing 8 Bolts Of Set Plate
      G02624497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE 
    1. Remove the fuel suction tube from the fuel tank.
      NOTE:
      • Do not damage the fuel pump filter.
      • Do not bend the arm of the fuel sender gage.
    2. Remove the gasket from the fuel suction tube.
      Fig 5: Removing Fuel Suction Tube From Fuel Tank
      G02624498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE VAPOR PRESSURE SENSOR ASSY 
    1. Remove the cover.
    2. Remove the tube joint clip, and pull out the vapor pressure sensor.
      Fig 6: Removing Vapor Pressure Sensor Assy
      G02624499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL SUCTION SUPPORT NO. 2 
    1. Using a screwdriver with its tip wrapped in tape, detach the 5 snap claws from the claw holes, and remove the fuel suction support.
    NOTE: Do not damage the fuel suction support.
    Fig 7: Detaching Fuel Suction Support No. 2
    G02624500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL PUMP CUSHION RUBBER 
    Fig 8: Removing Fuel Pump Cushion Rubber
    G02624501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL SENDER GAGE ASSY 
    1. Disconnect the fuel sender gage connector.
    2. Using a screwdriver with its tip wrapped in tape, unfasten the clamp to release the fuel sender gage. Slide the fuel sender gage to remove it from the fuel pump.
      Fig 9: Removing Fuel Sender Gage Assy
      G02624502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL SUCTION PLATE SUB-ASSY 
    1. Disconnect the fuel pump connector.
    2. Using a screwdriver with its tip wrapped in tape, detach the 4 snap claws from the claw holes, and pull out the fuel suction plate.
    NOTE: Do not damage the fuel suction support.
    Fig 10: Detaching Fuel Suction Plate Sub-Assy
    G02624503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL PUMP HARNESS 
    1. Disconnect the connector.
    2. Using a small screwdriver, pry out the fuel pump harness.
      Fig 11: Removing Fuel Pump Harness
      G02624504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL PUMP 
    1. Pull out the fuel pump from the fuel tank fuel filter.
      Fig 12: Pulling Out Fuel Pump From Fuel Tank Fuel Filter
      G02624505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL PUMP FILTER 
    1. Using a small screwdriver, pry out the clip.
    2. Pull out the fuel pump filter from the fuel pump.
      Fig 13: Removing Fuel Pump Filter
      G02624506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL PRESSURE REGULATOR ASSY 
    1. Pull out the fuel pressure regulator from the fuel tank fuel filter.
    2. Remove the O-ring from the fuel pressure regulator.
      Fig 14: Removing Fuel Pressure Regulator Assy
      G02624507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FUEL PRESSURE REGULATOR ASSY 
    1. Apply a light coat of gasoline or grease to a new O-ring, and install it to the fuel pressure regulator.
    2. Push in the fuel pressure regulator to the fuel tank fuel filter.
  17. INSTALL FUEL PUMP FILTER 
    1. Install the fuel pump filter with a new clip.
  18. INSTALL FUEL PUMP 
    1. Apply a light coat of gasoline or grease to the O-ring of the fuel pump.
    2. Push in the fuel pump to the fuel tank fuel filter.
  19. INSTALL FUEL PUMP HARNESS 
  20. INSTALL FUEL SUCTION PLATE SUB-ASSY 
  21. INSTALL FUEL SENDER GAGE ASSY 
  22. INSTALL FUEL PUMP CUSHION RUBBER 
  23. INSTALL FUEL SUCTION SUPPORT NO. 2 
  24. INSTALL VAPOR PRESSURE SENSOR ASSY 
  25. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE 
    1. Install a new gasket to the fuel suction tube.
    2. Install the fuel suction tube.
    NOTE:
    • Do not damage the fuel pump filter.
    • Do not bend the arm of the fuel sender gage.
  26. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Align the mark of the set plate with the fuel suction tube.
    2. Install the set plate with the 8 bolts.

      Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf) 

      Fig 15: Installing Fuel Tank Vent Tube Set Plate
      G02624508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. CONNECT FUEL PUMP TUBE SUB-ASSY 
    1. Install the fuel pump tube with the tube joint clip.
    NOTE:
    • Check that there are no scratches or foreign objects on the connecting part.
    • Check that the fuel tube joint is inserted securely.
    • Check that the tube joint clip is on the collar of the fuel tube joint.
    • After installing the tube joint clip, check that the fuel tube joint has not been pulled off.
      Fig 16: Installing Fuel Pump Tube With Tube Joint Clip
      G02624509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION   ) 
  29. INSTALL REAR FLOOR SERVICE HOLE COVER 
  30. INSTALL REAR SEAT CUSHION ASSEMBLY (See  OVERHAUL  ) 
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