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Home >> Toyota >> 2004 >> Matrix Base, 4WD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Engine Fuel System >> Fuel Pump ASSY (Ff) >> Components >> Removal & Installation
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Removal & Installation

  1. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY 
    1. Remove the 2 installing bolts of the rear seat cushion.
    Fig 1: Removing 2 Installing Bolts Of Rear Seat Cushion
    G00922759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear service hole cover.
      Fig 2: Removing Rear Service Hole Cover
      G00922760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pump and vapor pressure sensor connector.
    Fig 3: Disconnecting Fuel Pump & Vapor Pressure Sensor Connector
    G00922761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT 
    1. Start the engine.
    2. After the engine has stopped on the its own, turn the ignition switch to lock.
  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    Fig 4: Disconnecting Fuel Tank Main Tube Sub-Assy
    G00922762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the tube joint clip, and pull out the fuel tank main tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube joint before this work and clean dirt away.
    • Be careful of dirt like mud because the fuel tube joint has an O-ring to seal the fuel tube connector and fuel suction plate.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube joint with a vinyl bag.
    • When the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.
    5. Fig 5: Removing Fuel Tube Joint
    G00922763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT FUEL EMISSION TUBE SUB-ASSY No. 1 
    Fig 6: Disconnecting Fuel Emission Tube Sub-Assy No. 1
    G00922764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pinch the fuel tube connector clip and then pull out the fuel emission tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube connector before this work and clean dirt away.
    • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube connector with a vinyl bag.
      • Fig 7: View Of Disconnecting Fuel Tube Connector
      G00922765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • When the fuel tube connector and pipe are stuck, pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.
  6. REMOVE FUEL TANK VENT TUBE SET PLATE 
    Fig 8: Removing Fuel Tank Vent Tube Set Plate
    G00922766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 8 bolts and fuel tank vent tube set plate.
  7. REMOVE FUEL PUMP ASSEMBLY 
    Fig 9: Removing Fuel Pump Assembly
    G00922767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pull out the fuel pump assembly.
    NOTE:
    • Do not damage the fuel pump filter.
    • Be careful that the arm of the fuel sender gauge should not bent.
  8. REMOVE FUEL SUCTION TUBE SET GASKET 
    1. Remove the gasket from the fuel pump assembly.
    Fig 10: Removing Gasket From Fuel Pump Assembly
    G00922768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL SUCTION SUPPORT No. 2 
    1. Using a screwdriver, disconnect the 5 snap claws from the claw holes, and remove the fuel suction support.
      2. Fig 11: Disconnecting Snap Claws Using Screwdriver
      G00922769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not damage the fuel suction support.
  10. REMOVE FUEL PUMP CUSHION RUBBER 
    Fig 12: Removing Fuel Pump Cushion Rubber
    G00922770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the fuel pump cushion rubber.
  11. REMOVE FUEL SENDER GAGE ASSY 
    1. Disconnect the fuel sender gage connector.
    2. Using a screwdriver, unlock the fuel sender gage, and slide it to remove.
    Fig 13: Unlocking Fuel Sender Gage Using Screwdriver
    G00922771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL SUCTION PLATE SUB-ASSY 
    1. Disconnect the fuel pump connector.
    2. Using a screwdriver, disconnect the 4 snap claws from the claw holes, and remove the fuel suction plate.
      Fig 14: Disconnecting Snap Claws Using Screwdriver
      G00922772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not damage the fuel suction plate.
  13. REMOVE VAPOR PRESSURE SENSOR ASSY 
    1. Remove the tube joint clip, and pull out the vapor pressure sensor.
    Fig 15: Removing Tube Joint Clip
    G00922773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL PUMP HARNESS 
    1. Remove the fuel pump harness from the fuel suction plate.
    Fig 16: Removing Fuel Pump Harness From Fuel Suction Plate
    G00922774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL PUMP 
    Fig 17: Removing Fuel Pump
    G00922775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pull out the fuel pump from the fuel filter.
  16. REMOVE FUEL PUMP FILTER 
    Fig 18: Removing Fuel Pump Filter
    G00922776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a small screwdriver, pry out the clip.
    2. Pull out the fuel pump filter from the fuel pump.
  17. REMOVE FUEL PRESSURE REGULATOR ASSY 
    Fig 19: Removing Fuel Pressure Regulator Assy
    G00922777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pull out the fuel pressure regulator from the fuel filter.
  18. REMOVE FUEL PRESSURE REGULATOR O-RING 
    1. Remove an O-ring from the fuel pressure regulator.
    Fig 20: Removing Fuel Pressure Regulator O-Ring
    G00922778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FUEL PRESSURE REGULATOR O-RING 
    1. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
    Fig 21: Applying Light Coat Of Gasoline To New O-Ring
    G00922779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FUEL PUMP FILTER 
    1. Install the fuel pump filter with a new clip.
  21. INSTALL FUEL PUMP 
    1. Apply a light coat of gasoline to an O-ring, and install the fuel pump to the fuel filter.
    Fig 22: Applying Light Coat Of Gasoline To O-Ring
    G00922780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL VAPOR PRESSURE SENSOR ASSY 
    1. Install the vapor pressure sensor with the tube joint clip.
    NOTE:
    • Check that there is no scratch or foreign objects on the connecting parts.
    • Check that the fuel tube joint is inserted fully and securely.
    • Check that the tube joint clip is on the collar of the fuel tube joint.
    • After installing the tube joint clip, check that the fuel tube joint connector is not pulled off.
  23. INSTALL FUEL SUCTION TUBE SET GASKET 
    1. Install a new gasket to the fuel pump assembly.
  24. INSTALL FUEL PUMP ASSEMBLY 
    1. Install the fuel pump assembly to the fuel tank.
    NOTE:
    • Do not damage the fuel pump filter.
    • Be careful that the arm of the fuel sender gauge should not bent.
  25. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the fuel tank vent tube set plate with the 8 bolts.
      1. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 
  26. CONNECT FUEL EMISSION TUBE SUB-ASSY No. 1 
    1. Push in the fuel emission tube to the pipe until fuel tube connector makes "click" sound.
    NOTE:
    • Check if there is any damage or foreign objects on the connected part.
    • After connecting, check if the pipe and fuel tube connector are securely connected by pulling them.
  27. CONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    1. Connect the fuel tank main tube with the tube joint clip.
    NOTE:
    • Check that there is no scratch or foreign objects on the connecting parts.
    • Check that the fuel tube joint is inserted fully and securely.
    • Check that the tube joint clip is on the collar of the fuel tube joint.
    • After installing the tube joint clip, check that the fuel tube joint is not pulled off.
  28. CHECK FUEL LEAK (See   FUEL SYSTEM   ) 
  29. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Using the butyl tape, install the rear floor service hole cover.
    Fig 23: Installing Rear Floor Service Hole Cover Using Butyl Tape
    G00922781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY 
    1. Install the rear seat cushion with the 2 bolts.
      1. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) 
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