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Home >> Toyota >> 2019 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 14 (Fuel System (1AR-FE) (Service Information) (Except Hybrid)) >> Fuel Pump >> Removal [12/2013 - ] >> Procedure

Removal [12/2013 - ]: Procedure

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  1. PRECAUTION 
    NOTE:

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

    Refer to PRECAUTION [12/2013 - 11/2016] , or refer to PRECAUTION [11/2016 - ]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [12/2013 - 11/2016] , or refer to PRECAUTION [11/2016 - ]

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [12/2013 - 11/2016] , or refer to INITIALIZATION [11/2016 - ]

  4. REMOVE REAR NO. 1 SEAT ASSEMBLY 

    for Captain Seat Type: Refer to REMOVAL [12/2013 - ]

    for 60/40 Split Seat Type LH Side: Refer to REMOVAL [12/2013 - ]

    for 60/40 Split Seat Type RH Side: Refer to REMOVAL [12/2013 - ]

  5. REMOVE DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 1 , or refer to PROCEDURE - Step 1 , or refer to PROCEDURE - Step 1

  6. REMOVE NO. 3 DECK BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2 , or refer to PROCEDURE - Step 2 , or refer to PROCEDURE - Step 2

  7. REMOVE DECK SIDE TRIM BOX LH 

    Refer to PROCEDURE - Step 3 , or refer to PROCEDURE - Step 3 , or refer to PROCEDURE - Step 3

  8. REMOVE REAR DECK FLOOR BOX 

    Refer to PROCEDURE - Step 4 , or refer to PROCEDURE - Step 4 , or refer to PROCEDURE - Step 4

  9. REMOVE REAR FLOOR FINISH PLATE 

    Refer to PROCEDURE - Step 5 , or refer to PROCEDURE - Step 5 , or refer to PROCEDURE - Step 5

  10. REMOVE REAR NO. 2 SEAT ASSEMBLY 

    Refer to REMOVAL [12/2013 - 11/2016] , or refer to REMOVAL [11/2016 - ]

  11. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 12 , or refer to PROCEDURE - Step 12 , or refer to PROCEDURE - Step 12

  12. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 

    Refer to PROCEDURE - Step 13 , or refer to PROCEDURE - Step 13 , or refer to PROCEDURE - Step 13

  13. REMOVE REAR DOOR SCUFF PLATE RH 

    Refer to PROCEDURE - Step 22 , or refer to PROCEDURE - Step 22 , or refer to PROCEDURE - Step 22

  14. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 

    Refer to PROCEDURE - Step 23 , or refer to PROCEDURE - Step 23 , or refer to PROCEDURE - Step 23

  15. REMOVE FRONT DECK SIDE TRIM COVER LH 

    Refer to PROCEDURE - Step 27 , or refer to PROCEDURE - Step 27 , or refer to PROCEDURE - Step 27

  16. DISCONNECT REAR NO. 1 SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 11 , or refer to PROCEDURE - Step 11

  17. REMOVE NO. 2 DECK SIDE TRIM COVER 

    Refer to PROCEDURE - Step 29 , or refer to PROCEDURE - Step 29 , or refer to PROCEDURE - Step 29

  18. REMOVE DECK TRIM SIDE SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 30 , or refer to PROCEDURE - Step 30 , or refer to PROCEDURE - Step 30

  19. DISCONNECT REAR NO. 2 SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 14 , or refer to PROCEDURE - Step 14

  20. REMOVE DECK TRIM POCKET COVER (for LH Side) 

    Refer to PROCEDURE - Step 32 , or refer to PROCEDURE - Step 32 , or refer to PROCEDURE - Step 32

  21. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (for LH Side) 

    Refer to PROCEDURE - Step 33 , or refer to PROCEDURE - Step 33 , or refer to PROCEDURE - Step 33

  22. REMOVE ROPE HOOK (for LH Side) 

    Refer to PROCEDURE - Step 34 , or refer to PROCEDURE - Step 34 , or refer to PROCEDURE - Step 34

  23. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH 

    Refer to PROCEDURE - Step 35 , or refer to PROCEDURE - Step 35 , or refer to PROCEDURE - Step 35

  24. REMOVE FRONT DECK SIDE TRIM COVER RH 

    Refer to PROCEDURE - Step 38 , or refer to PROCEDURE - Step 38 , or refer to PROCEDURE - Step 38

  25. DISCONNECT REAR NO. 1 SEAT OUTER BELT ASSEMBLY RH 

    Refer to PROCEDURE - Step 39 , or refer to PROCEDURE - Step 39 , or refer to PROCEDURE - Step 39

  26. REMOVE NO. 1 DECK SIDE TRIM COVER 

    Refer to PROCEDURE - Step 40 , or refer to PROCEDURE - Step 40 , or refer to PROCEDURE - Step 40

  27. REMOVE DECK TRIM SIDE BELT HOLE COVER RH 

    Refer to PROCEDURE - Step 41 , or refer to PROCEDURE - Step 41 , or refer to PROCEDURE - Step 41

  28. DISCONNECT REAR NO. 2 SEAT OUTER BELT ASSEMBLY RH 

    Refer to PROCEDURE - Step 42 , or refer to PROCEDURE - Step 42 , or refer to PROCEDURE - Step 42

  29. REMOVE SIDE TRIM COVER RH (w/o Rear Automatic Air Conditioning System) 

    Refer to PROCEDURE - Step 43 , or refer to PROCEDURE - Step 43 , or refer to PROCEDURE - Step 43

  30. REMOVE COOLER (NO. 2 ROOM TEMP. SENSOR) THERMISTOR 

    Refer to PROCEDURE - Step 1

  31. REMOVE NO. 1 ROOM LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 1 , or refer to PROCEDURE - Step 1

  32. REMOVE DECK TRIM POCKET COVER (for RH Side) 

    Refer to PROCEDURE - Step 46 , or refer to PROCEDURE - Step 46 , or refer to PROCEDURE - Step 46

  33. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (for RH Side) 

    Refer to PROCEDURE - Step 47 , or refer to PROCEDURE - Step 47 , or refer to PROCEDURE - Step 47

  34. REMOVE ROPE HOOK (for RH Side) 

    Refer to PROCEDURE - Step 48 , or refer to PROCEDURE - Step 48 , or refer to PROCEDURE - Step 48

  35. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH 

    Refer to PROCEDURE - Step 49 , or refer to PROCEDURE - Step 49 , or refer to PROCEDURE - Step 49

  36. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Turn back the front floor carpet.
      GTY437483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear floor service hole cover and butyl tape.
      GTY437482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel pump connector.
  37. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.
      GTY438701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube
      Pull Off
      Pull Off
      NOTE:
      • Remove any 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 fuel pipe.
      • Only disconnect the fuel tube joint by hand.
      • Do not forcibly bend, twist or turn the nylon 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 sub-assembly are stuck, push and pull to release them.
  38. REMOVE FUEL PUMP GAUGE RETAINER 
    NOTE:

    Before performing these procedures, first cover the connector and fuel tube joints of the fuel suction tube with pump and gauge assembly with vinyl tape and then clean any dirt and foreign matter in order to prevent contamination of the fuel system.

    1. Install SST (fuel pump holding tool assy) to the fuel pump gauge retainer.
      1. Insert SST (claw No. 1) between the service hole and fuel pump gauge retainer as shown in the illustration.
        GTY474120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b Wide
        • SST: 09808-14050 
          1. 09882-14050
      2. Align the detent of the tank suction tube support and cut out of SST (claw No. 1).
        GTY477176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b Detent of Tank Suction Tube Support
        Front - -
      3. Insert SST (claw) between the service hole and fuel pump gauge retainer as shown in the illustration.
        GTY475716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b SST (Claw)
        • SST: 09808-14040 
          1. 09882-14040
      4. Use the same procedure as for SST (claw No. 1), insert SST (claw No. 2) between the service hole and fuel pump gauge retainer, and align it with the second detent of the tank suction tube support.
        GTY473373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b SST (Claw No. 2)
        *c SST (Bridge) *d SST (Bolt)
        *e Narrow *f Contact
        *g Cloth *h Detent of Tank Suction Tube Support
        • SST: 09808-14050 
          1. 09881-14050
          2. 09882-14050
          3. 09883-14050
          4. 09884-14050
      5. Install SST (bridge) to SST (claw No. 1) and SST (claw No. 2) with the 2 SST (bolt).
      6. Place a piece of cloth or equivalent on the fuel suction tube with pump and gauge assembly and lightly tighten the 2 SST (bolt) of SST (bridge) until they come into contact with the fuel suction tube with pump and gauge assembly.
        NOTE:

        If a piece of cloth or equivalent is not placed between the fuel suction tube with pump and gauge assembly and the 2 SST (bolt), the fuel suction tube with pump and gauge assembly may be damaged.

    2. Install SST (fuel pump retainer tool assy) to the fuel pump gauge retainer.
      1. Position SST (claw) next to SST (claw No. 1) so that the protrusions of the fuel pump gauge retainer are aligned with the grooves of SST (claw). Use the same procedure as for the previous SST (claw), insert the second SST (claw) between the service hole and fuel pump gauge retainer, and position it next to SST (claw No. 2) so that it is opposite to SST (claw) and the protrusions of the fuel pump gauge retainer are aligned with the grooves of SST (claw).
        GTY481457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b SST (Claw No. 2)
        *c SST (Claw) *d SST (Bridge)
        *e Triangle Mark *f Protrusion of Fuel Pump Gauge Retainer
        *g Groove of SST (Claw) *h Correct
        *i Incorrect - -
        • SST: 09808-14040 
          1. 09882-14040
        NOTE:

        Ensure that SST (claw) does not cover the triangle mark of the fuel pump gauge retainer.

      2. While ensuring that SST (plate) is centered, install SST (plate) to 2 SST (claw) with the 2 SST (bolt and washer set).
        GTY474747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1)
        *b SST (Claw No. 2)
        *c SST (Claw)
        *d SST (Bridge)
        *e SST (Plate)
        *f SST (Bolt and Washer Set)
        • SST: 09808-14040 
          1. 09881-14040
          2. 09883-14040
    3. Attach 2 breaker bars to SST (fuel pump holding tool assy) and 1 breaker bar to SST (fuel pump retainer tool assy).
      GTY472657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Fuel Pump Holding Tool Assy)
      *b SST (Fuel Pump Retainer Tool Assy)
    4. Place paint marks on the fuel suction tube with pump and gauge assembly, fuel pump gauge retainer and fuel tank assembly as shown in the illustration.
      GTY480858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
    5. While holding the 2 breaker bars attached to SST (fuel pump holding tool assy), turn the breaker bar attached to SST (fuel pump retainer tool assy) to loosen the fuel pump gauge retainer. [*1]
      GTY482239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Fuel Pump Holding Tool Assy) *b SST (Fuel Pump Retainer Tool Assy)
      *c Holding *d Turn
      *e Press down - -
      NOTE:

      Press down on the 2 locations shown in the illustration to prevent SST (fuel pump holding tool assy) from turning.

    6. Check that only the paint mark on the fuel pump gauge retainer has moved.
      GTY477433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Correct
      *c Incorrect - -

      HINT: 

      If the paint mark on the fuel suction tube with pump and gauge assembly has also moved, tighten the fuel pump gauge retainer until the paint marks are aligned at the original position. Then repeat from step [*1].

    7. Loosen the fuel pump gauge retainer by using SST (fuel pump retainer tool assy) until the fuel pump gauge retainer turns approximately 360°.
      GTY480764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Claw) *b SST (Fuel Pump Holding Tool Assy)
      *c SST (Fuel Pump Retainer Tool Assy) - -
    8. Remove SST (fuel pump retainer tool assy) and SST (fuel pump holding tool assy) from the fuel pump gauge retainer.
    9. Check that the fuel pump gauge retainer can be loosened by hand.

      HINT: 

      If the fuel pump gauge retainer cannot be loosened by hand, use SST (fuel pump retainer tool assy) to loosen the fuel pump gauge retainer.

      GTY479372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Fuel Pump Retainer Tool Assy) - -
      • SST: 09808-14040 
        1. 09881-14040
        2. 09882-14040
        3. 09883-14040
    10. While holding the fuel suction tube with pump and gauge assembly by hand, remove the fuel pump gauge retainer.
  39. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    1. Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.
      NOTE:

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

    2. Remove the fuel suction tube set gasket from the fuel tank assembly.
      GTY449718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Suction Tube Set Gasket
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