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Fuel Pump: Removal: Removal

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

  2. REMOVE REAR SEAT CUSHION ASSEMBLY  . Refer to REMOVAL - Step 4
  3. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear floor service hole cover.
      Fig 1: Identifying Rear Floor Service Hole Cover
      GTY217927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pump connector.
      Fig 2: Identifying Fuel Pump Connector
      GTY217993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION

  5. REMOVE REAR NO. 3 FLOOR BOARD  . Refer to REMOVAL - Step 2
  6. REMOVE DECK FLOOR BOX RH  . Refer to REMOVAL - Step 3
  7. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

  8. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the tube joint clip and disengage the No. 1 fuel tube clamp, then pull the fuel tube joint out of the plug of the fuel suction tube assembly.
      Fig 3: Identifying Fuel Tube Joint, Joint Clip, Clamp & O-Rings
      GTY329662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Tube Joint Clip
      *2 No. 1 Fuel Tube Clamp
      *3 Fuel Tube Joint
      *4 O-ring
      NOTE:
      • Remove any dirt or foreign matter on the fuel tube joint before performing this work.
      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has O-rings that seal the pipe.
      • Only disconnect the fuel tube joint by hand.
      • Do not forcibly bend, twist or turn the fuel tube.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint.
      • If the fuel tube joint and fuel suction plate are stuck, push and pull to release them.
  9. REMOVE NO. 1 FUEL TUBE CLAMP 
    1. Disengage the claw and remove the No. 1 fuel tube clamp.
      Fig 4: Identifying No. 1 Fuel Tube Clamp
      GTY332274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Claw
  10. REMOVE FUEL PUMP GAUGE RETAINER 
    1. Temporarily install the SST plate and claws to the fuel pump gauge retainer.
      Fig 5: Identifying Fuel Pump Gauge Retainer & SST
      GTY292099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 SST
      (Plate)
      *2 SST
      (Claw)
      • SST: 09808-14030 
        1. 09808-01030
        2. 09808-01040
        3. 09808-01050

      HINT: 

      • Engage the SST claws securely with the fuel pump gauge retainer holes to secure SST.
      • Make sure that only 2 claws are used with SST.
    2. While pressing the claws of SST to the fuel pump gauge retainer holes securely, tighten the bolts.

      HINT: 

      Install SST while pressing the SST claws toward the fuel pump gauge retainer (towards the center of SST).

    3. Install the SST handle.
    4. Lightly press down on SST to prevent it from separating from the retainer. While pressing SST, rotate the handle slowly to loosen the retainer.
      Fig 6: Removing Fuel Pump Retainer
      GTY293555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 SST
      (Handle)
      *2 SST
      (Plate)
      *3 SST
      (Claw)
      • SST: 09808-14030 
        1. 09808-01010
        2. 09808-01020
        3. 09808-01030
        4. 09808-01040
        5. 09808-01050
      NOTE:
      • Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
      • Loosen the retainer by turning it counterclockwise while holding SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank.
      • Make sure to rotate the SST handle horizontally. If the SST handle is rotated at an angle, SST may come off.
      • Do not spin SST too fast or use an impact wrench as this may result in damage to components.
      • If SST comes off of the retainer, loosen the SST bolts and reinstall SST.

      HINT: 

      The holes on the fuel pump gauge retainer can be fitted into the tips of SST.

    5. Remove the fuel pump gauge retainer while holding the fuel suction tube assembly by hand.
  11. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    1. Remove the fuel suction tube with pump and gauge assembly from the fuel tank.
      Fig 7: Identifying Fuel Suction Tube Assembly With Pump And Gauge
      GTY226220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the fuel sender gauge arm does not bend.

    2. Remove the fuel suction tube set gasket from the fuel tank.
      Fig 8: Identifying Fuel Tank Gasket
      GTY211102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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