Fuel Pump: Removal

NOTE: Do not disconnect the hose indicated in the illustration.

REMOVE FUEL TANK ASSEMBLY
1. Remove the fuel tank assembly (See REMOVAL ).
  
  Fig 1: Identifying Fuel Tank Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Remove the tube joint clip and disconnect the fuel tank main tube.
  NOTE:
  - Before removing the tube joint clip, check for foreign matter around the clip. Clean if necessary.
  - Keep the O-ring free of foreign matter, as it becomes contaminated easily.
  - Do not use any tools in this procedure.
  - Do not forcefully bend, kink or twist the tube.
  - Put the end of the tube in a plastic bag to prevent damage and contamination.
  - If the fuel suction plate and tube are stuck together, pinch the tube and turn it carefully to disconnect it.
  - Be careful not to damage the clip. If the clip is damaged, replace it.
    
    Fig 2: Removing Joint Clip And Fuel Tank Main Tube
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TANK VENT TUBE SET PLATE
1. Remove the 8 bolts, tube clamp and set plate.
  
  Fig 3: Locating Set Plate With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SUCTION WITH PUMP ASSEMBLY
1. Disconnect the fuel hose and remove the fuel suction with pump from the fuel tank.
  NOTE: Do not damage the fuel suction with pump.
  
  Fig 4: Disconnecting Fuel Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gasket from the fuel suction plate.
  
  Fig 5: Identifying Fuel Suction Plate Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 FUEL SUB-TANK
1. Disconnect the wire harness.
  
  Fig 6: Identifying No. 1 Fuel Sub-Tank Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using needle-nose pliers, remove the E-ring.
  HINT:
  
  Slightly lower the fuel suction plate to remove the E-ring.
  
  Fig 7: Removing E-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. for TMC Made:
  Remove the 2 springs from the 2 shafts.
  
  Fig 8: Removing Springs From Shafts - For TMC Made
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. for TMMC Made:
  Remove the spring from the shaft.
  
  Fig 9: Removing Spring From Shaft - For TMMC Made
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Detach the 2 claws and remove the No. 1 fuel sub-tank.
  
  Fig 10: Removing No. 1 Fuel Sub-Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Detach the claw of the jet pump nozzle and remove the jet pump nozzle.
7. Using a screwdriver, remove the jet pump.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 11: Removing Jet Pump Nozzle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the O-ring from the jet pump.
  
  Fig 12: Removing O-Ring From Jet Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 FUEL SUCTION SUPPORT
1. Using needle-nose pliers, detach the 2 claws and remove the No. 1 fuel suction support.
  
  Fig 13: Removing No. 1 Fuel Suction Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL PUMP ASSEMBLY
1. Detach the 5 claws on the filter and remove the fuel pump from the fuel filter.
  HINT:
  
  When detaching the claws, do not disconnect the fuel main tube.
  
  Fig 14: Identifying Fuel Pump Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the fuel pump connector.
  
  Fig 15: Locating Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring from the fuel filter.
4. Remove the fuel pump spacer from the fuel pump assembly.
  
  Fig 16: Identifying Fuel Pump Spacer And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002