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Fuel Pump ASSY (3MZ-FE): Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM (3MZ-FE)  ) 
  2. REMOVE DECK BOARD SUB-ASSY 
    1. Disengage the 5 clips and turn up the front side of the deck board.
    Fig 1: Disengaging Clips
    G02596910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE REAR SEAT TRACK BRACKET COVER OUTER 
  4. REMOVE REAR SEAT ASSY RH (See  OVERHAUL  ) 
  5. REMOVE REAR SEAT ASSY LH (See  OVERHAUL  ) 
  6. REMOVE REAR DOOR SCUFF PLATE LH 
  7. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear floor service hole cover.
    2. Disconnect the fuel pump & sender gauge connector.
    Fig 2: Removing Rear Floor Service Hole Cover
    G02596911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE 
    1. Disconnect the fuel pump tube.
      1. Remove the tube joint clip, and pull out the fuel pump tube.
      Fig 3: Removing Tube Joint Clip
      G02596912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.
      • Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
      • 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 it. Then pull the connector from the pipe.
      Fig 4: Identifying Fuel Tube Joint
      G02596913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, loosen the fuel pump gage retainer.

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)

      HINT:

      A rib on the fuel pump gage retainer can be fitted into a tip of the SST.

    3. Remove the fuel pump gage retainer.
      Fig 5: Loosening Fuel Pump Gage Retainer Using SST
      G02596914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the fuel suction tube.
      NOTE: Be careful not to bend the arm of the fuel sender gage.
    5. Remove the gasket from the fuel tank.
    Fig 6: Removing Fuel Suction Tube
    G02596915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL SENDER GAGE ASSY 
    1. Disconnect the fuel sender gage connector.
    2. Unlock the fuel sender gage and slide it to remove.
    Fig 7: Unlocking Fuel Sender Gage
    G02596916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL SUCTION PLATE SUB-ASSY 
    1. Using a screwdriver with the its 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 fuel suction support No. 1.
    Fig 8: Removing Fuel Suction Plate
    G02596917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL PUMP ASSY 
    1. Disconnect the fuel pump connector.
    2. Using a small screwdriver with the its wrapped in tape, disconnect the 2 snap-claws from the claw holes and pull out the fuel pump.
      NOTE: Do not damage the fuel pump and fuel suction plate.
    3. Remove the O-ring and fuel pump spacer from the fuel pump.
    Fig 9: Disconnecting Snap-Claws From Claw Holes
    G02596918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL PUMP FILTER 
    1. Using a small screwdriver, pry out the clip.
    2. Remove the fuel filter from the fuel pump.
    Fig 10: Prying Out Clip Using Small Screwdriver
    G02596919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TUBE JOINT NO. 1 
    1. Disconnect the connector.
    2. Using a screwdriver with the its wrapped in tape, disconnect the snap-claw from the claw hole and pull out the fuel tube joint.
    NOTE: Do not damage the fuel tube joint and fuel suction plate.
    Fig 11: Disconnecting Snap-Claw From Claw Hole
    G02596920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL PUMP HARNESS 
    1. Remove the harness from the fuel tube joint No. 1.
    Fig 12: Removing Harness From Fuel Tube Joint No. 1
    G02596921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL PRESSURE REGULATOR ASSY 
    1. Remove the clip.
    2. Pull out the pressure regulator from the fuel tube joint No. 1.
    3. Remove the 2 O-rings from the fuel tube joint No. 1.
    Fig 13: Removing Clip
    G02596922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FUEL PRESSURE REGULATOR ASSY 
    1. Apply a light coat of gasoline or spindle oil to the 2 new O-rings, and install them to the fuel pressure regulator.
    2. Apply a light coat of gasoline or spindle oil to the 2 O-rings again, and install the fuel pressure regulator to the fuel tube joint No. 1.
    3. Install the clip.
    Fig 14: Identifying O-Ring
    G02596923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FUEL PUMP HARNESS 
  18. INSTALL FUEL TUBE JOINT NO. 1 
    1. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel tube joint No. 1.
    2. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel tube joint No. 1 to the fuel suction plate.
    3. Connect the connector.
    Fig 15: Installing Fuel Tube Joint No. 1
    G02596924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FUEL PUMP FILTER 
    1. Install the fuel filter with a new clip
  20. INSTALL FUEL PUMP ASSY 
    1. Install the fuel pump spacer to the fuel pump.
    2. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel pump.
    3. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel pump to the fuel suction plate.
    4. Connect the fuel pump connector.
    Fig 16: Installing Fuel Pump Assy
    G02596925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FUEL SUCTION PLATE SUB-ASSY 
    1. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel tube joint No. 1.
    2. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel suction plate to the fuel suction support No. 1.
    Fig 17: Identifying O-Ring
    G02596926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL FUEL SENDER GAGE ASSY 
  23. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE 
    1. Install a new gasket to the fuel tank.
    2. Attach the fuel suction tube to the fuel tank.
      NOTE: Be careful not to bend the arm of the fuel sender gage.
      Fig 18: Identifying Keyway And Key
      G02596927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the keyway of the fuel suction tube support with the key of the fuel suction tube.
    4. Apply MP grease to the entire interior surface of the fuel pump gage retainer.
    5. Align the triangle mark on new fuel pump gauge retainer with the "S" mark on the fuel tank while pushing down the fuel suction tube, attach the fuel pump gauge retainer.
      Fig 19: Identifying Triangle And S Mark
      G02596928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Rotate the fuel pump gage retainer by hand, then tighten it one complete turn and half using SST. Triangle mark on the fuel pump gauge retainer must be positioned between "A" and "MAX." indications on the fuel tank.
      NOTE: Do not use other tools in this operation. Damage to the fuel pump gage retainer and the fuel tank may result.

      HINT:

      A rib on the fuel pump gage retainer can be fitted into a tip of the SST.

      Fig 20: Identifying Triangle Mark Position
      G02596929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the fuel pump tube.
      1. Install the fuel pump tube and 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 21: Installing Fuel Pump Tube And Tube Joint Clip
      G02596930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  25. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Install a new butyl tape to the rear floor service hole cover.
    2. Connect the fuel pump & sender gage connector.
    3. Install the rear floor service hole cover.
    Fig 22: Installing Rear Floor Service Hole Cover
    G02596931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REAR DOOR SCUFF PLATE LH 
  27. INSTALL REAR SEAT ASSY LH (See  OVERHAUL  ) 
  28. INSTALL REAR SEAT ASSY RH (See  OVERHAUL  ) 
  29. INSTALL REAR SEAT TRACK BRACKET COVER OUTER 
  30. INSTALL DECK BOARD SUB-ASSY 
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