Fuel Pump: Removal

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE FUEL TANK ASSEMBLY
1. Remove the fuel tank (see REMOVAL ).
REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Remove the joint clip and fuel tank main tube.
  CAUTION:
  - 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 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 the clip. If the clip is damaged, replace it.
    
    Fig 1: 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 and set plate.
  
  Fig 2: Identifying 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 pump from the fuel tank.
  NOTE: Do not damage the fuel pump.
  
  Fig 3: Removing Fuel Pump From Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gasket from the fuel pump.
  
  Fig 4: Identifying Gasket From Fuel Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SUB-TANK ASSEMBLY
1. Disconnect the wire harness.
  
  Fig 5: Identifying Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using needle nose pliers, remove the E-ring.
  HINT:
  
  Slightly lower the sub-tank to remove the E-ring.
  
  Fig 6: Removal/Installation Of E-Ring Using Needle Nose Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 springs from the 2 shaft.
  
  Fig 7: Identifying Springs From Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Detach the 2 claws and remove the sub-tank.
  
  Fig 8: Identifying Sub-Tank Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disengage the claw of the jet pump nozzle.
6. Using a screwdriver with the tip taped, remove the jet pump.
  
  Fig 9: Removing Jet Pump Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the O-ring from the jet pump.
  
  Fig 10: Identifying O-Ring From Jet Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRACKET
1. Using a screwdriver, detach the 2 claws and remove the bracket.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 11: Identifying Bracket Claws
  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 removing the claw, do not disconnect the fuel main tube.
  
  Fig 12: Identifying Fuel Pump Filter Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the fuel pump connector.
  
  Fig 13: Identifying Fuel Pump Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring from the fuel filter.
  
  Fig 14: Identifying O-Ring From Fuel Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002