Fuel Pump: Removal

DISCONNECT BATTERY NEGATIVE TERMINAL
REMOVE REAR SEAT CUSHION ASSEMBLY RH
1. Remove the 2 installing bolts of the rear seat cushion.
  
  Fig 1: Locating Rear Seat Cushion Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR FLOOR SERVICE HOLE COVER
1. Remove the 4 screws, then remove the rear floor service hole cover (A).
2. Disconnect the fuel pump connector (B).
3. Discharge the fuel system pressure (C).
  1. Connect the battery negative terminal.
    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  2. Start the engine.
  3. Turn the ignition switch off after the engine stops.
    HINT:
    
    DTC P0171 (system to lean) may be present.
    
    Fig 2: Locating Rear Floor Service Hole Cover Screws
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Crank the engine again, and check that the engine does not start.
  5. Remove the fuel tank cap, and discharge the pressure remaining in the fuel tank completely.
  6. Disconnect the battery negative terminal.
REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
1. Disconnect the fuel tank main tube.
  1. Remove the tube joint clip, then pull the fuel tube joint out of the plug of the fuel suction plate.
    NOTE:
    Check that there is no dirt or other foreign objects around the fuel tube joint before disconnecting it. Clean the joint if necessary.
    
    It is necessary to prevent mud or dirt from entering the joint. If mud or dirt gets in the joint, the O-rings may not seal properly.
    
    Only disconnect the joint by hand.
    
    Do not bend, kink or twist the nylon tubes.
    
    Protect the joint by covering it with a plastic bag.
    
    Fig 3: Disconnecting Fuel Tank Main Tube
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the fuel tank vent hose.
  1. Pinch the retainer and pull the fuel tank vent connector out of the fuel tank to disconnect the fuel tank vent hose from the fuel suction plate.
    NOTE:
    Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
    
    It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
    
    Only disconnect the quick connector by hand.
    
    Do not bend, kink or twist the nylon tubes.
    
    Protect the connector by covering it with a plastic bag.
    
    If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
    
    Fig 4: Disconnecting Fuel Tank Vent Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, loosen the fuel pump gauge retainer.
  SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
  
  NOTE: Using SST. Do not use any other tools such as a screwdriver.
  
  HINT:
  
  Insert the notch of SST into the rib of the fuel pump gauge retainer.
4. Remove the fuel pump gauge retainer while holding the fuel suction tube by hand.
  
  Fig 5: Loosening Fuel Pump Gauge Retainer Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the fuel suction tube from the fuel tank.
  NOTE: Make sure that the fuel sender gauge arm does not bend.
  
  Fig 6: Locating Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the gasket from the fuel tank.
  
  Fig 7: Locating Fuel Tank Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SENDER GAUGE ASSEMBLY
1. Disconnect the fuel sender gauge connector (A).
2. Release the claw. Then slide the fuel sender gauge to remove it from the fuel filter (B).
  
  Fig 8: Locating Fuel Sender Gauge Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
1. Remove the E-ring.
  
  Fig 9: Locating E-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Release the claw, then remove the fuel pump filter.
  
  Fig 10: Identifying Fuel Pump Filter Claw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Release the 2 claws, then remove the fuel suction plate and spring.
  
  Fig 11: Identifying Fuel Suction Plate Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP HARNESS
1. Disconnect the 2 fuel pump harness connectors.
  
  Fig 12: Locating Fuel Pump Harness Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 FUEL SUCTION SUPPORT
1. Using a screwdriver with its tip wrapped with tape, release the 2 claws. Then remove the No. 1 fuel suction support.
  
  Fig 13: Removing No. 1 Fuel Suction Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP FILTER
1. Using a screwdriver with its tip wrapped with tape, release the 5 claws. Then remove the fuel pump filter.
  NOTE: Do not damage the fuel pump filter or fuel filter.
  
  Fig 14: Removing Fuel Pump Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
1. Pull the fuel pressure regulator out of the fuel filter.
  
  Fig 15: Pulling Fuel Pressure Regulator Out Of Fuel Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 O-rings from the fuel pressure regulator.
  
  Fig 16: Identifying O-Rings On Fuel Pressure Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP
1. Pull the fuel pump out of the fuel filter.
  
  Fig 17: Pulling Fuel Pump Out Of Fuel Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the fuel pump.
  
  Fig 18: Locating O-Ring On Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002