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Fuel Pump ASSY: Replacement

WARNING: This page is about a different car, the 2004 Toyota Camry Solara. 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  REAR SEAT ASSY (40/60 FOLDING)  ) 
  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
    G02588907Courtesy 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
    G02588908Courtesy 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: Checking Connector For Dirt, Mud Or Other Contamination
    G02588909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and set plate.
    Fig 4: Removing Set Plate
    G02588910Courtesy 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
    G02588911Courtesy 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 Assembly
    G02588912Courtesy 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: Removing Fuel Suction Support No. 2
    G02588913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL PUMP CUSHION RUBBER 
    Fig 8: Removing Fuel Pump Cushion Rubber
    G02588914Courtesy 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 Assembly
    G02588915Courtesy 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: Removing Fuel Suction Plate Sub-Assembly
    G02588916Courtesy 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: Prying Fuel Pump Harness
    G02588917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL PUMP 
    1. Pull out the fuel pump from the fuel tank fuel filter.
    Fig 12: Removing Fuel Pump
    G02588918Courtesy 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: Prying Clip
    G02588919Courtesy 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
    G02588920Courtesy 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 Set Plate
    G02588921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. CONNECT FUEL PUMP TUBE SUB-ASSY 
    1. Install the fuel pump tube with the tube joint clip.
    Fig 16: Installing Fuel Pump Tube With Tube Joint Clip
    G02588922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  28. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION   ) 
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