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Fuel Pump: Removal

WARNING: This page is about a different car, the 2008 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See FUEL SYSTEM .

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE REAR SEAT CUSHION ASSEMBLY  (See REMOVAL )
  4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER 
    1. Remove the No. 2 rear floor service hole cover and disconnect the fuel suction tube connector.
    Fig 1: Identifying No. 2 Rear Floor Service Hole Cover
    G05750054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Disconnect the connector from the fuel suction with pump and gauge assembly.
    2. Disconnect fuel pump tube.
      NOTE: Before beginning this procedure, check for foreign matter on the joint clips. Clean if necessary.
      Fig 2: Locating Fuel Suction With Pump Connector
      G05750055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 2 tube joint clips, fuel tank main tube and fuel tank return vent tube.
      NOTE:
      • 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 or twist the tube.
      • Put 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 any clips. If a clip is damaged, replace it.
      Fig 3: Removing Tube Joint Clips, Fuel Tank Main Tube And Fuel Tank Return Vent Tube
      G05826382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 8 bolts and the fuel tank vent tube set plate.

      HINT:

      While holding the fuel suction tube by hand, remove the fuel tank vent tube set plate.

      Fig 4: Locating Fuel Tank Vent Tube Set Plate Bolts
      G05750057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the fuel tube.
    5. Remove the fuel suction tube from the fuel tank.

      HINT:

      • Make sure that the fuel sender gauge arm does not bend.
      • Do not damage the No. 2 fuel hose.
      Fig 5: Removing Fuel Suction Tube From Fuel Tank
      G05303283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Disconnect the fuel sender gauge connector.
    2. Press down on the sender gauge claw labeled A. Then slide the sender gauge upward.
    Fig 6: Removing Fuel Sender Gauge Assembly
    G05826385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE NO. 1 FUEL SUB-TANK 
    1. Using needle nozzle pliers, remove the E-ring.
      Fig 7: Identifying E-Ring
      G05303230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with the tip taped, disengage the claw and remove the jet pump nozzle.
      Fig 8: Disengaging Claw And Remove Jet Pump Nozzle
      G05303231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver with the tip taped, disengage the 3 claws and remove the No. 1 sub-tank.
      Fig 9: Disengaging Claws And Remove No. 1 Sub-Tank
      G05826388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a clip remover with the tip taped, remove the jet pump and No. 1 fuel sub-tank.
    NOTE: The O-ring is installed firmly between the jet pump and No. 1 fuel sub-tank. Therefore, the jet pump and No. 1 fuel sub-tank should be removed carefully using a clip remover.
    Fig 10: Removing Jet Pump And No. 1 Fuel Sub-Tank
    G05303233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL PUMP 
    1. Disconnect the 2 connectors and terminal and remove the fuel pump wire.
      Fig 11: Locating Connectors And Terminal And Fuel Pump Wire
      G05287014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with the tip taped, detach the 2 claws from the claw holes and remove the fuel pump.
      Fig 12: Detaching Claws From Claw Holes
      G05303235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the fuel pump seal from the fuel pump.
    NOTE: If the fuel pump seal still remains in the fuel filter, remove it using a wire tip (1 mm) that is formed as shown in the illustration. Be careful not to damage the sealing surface.
    Fig 13: Locating Fuel Pump Seal
    G05826392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FLANGE ASSEMBLY 
    1. Using a screwdriver with the tip taped, disengage the 2 claws and remove the flange assembly.
    Fig 14: Disengaging Claws And Remove Flange Assembly
    G05303237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL RELIEF VALVE ASSEMBLY 
    1. Using a screwdriver with the tip taped, disengage the claw and remove the fuel relief valve assembly.
    Fig 15: Disengaging Claw And Remove Fuel Relief Valve Assembly
    G05303238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE JET PUMP 
    1. Using a screwdriver with the tip taped, disengage the 2 claws and remove the jet pump.
    Fig 16: Disengaging Claws And Remove Jet Pump
    G05303239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY 
    1. Remove the clip and fuel pressure regulator from the relief valve.
      Fig 17: Removing Clip And Fuel Pressure Regulator From Relief Valve
      G05303240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the fuel pressure regulator.
    Fig 18: Identifying Fuel Pressure Regulator O-Rings
    G04974932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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