REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4 and 5
The fuel pump and sending unit are one unit.
- Disconnect the negative battery cable.
- Position a suitable waste container under the fuel tank and drain the fuel from the tank.
- Remove the fuel tank.
- On non-All-Trac 4-Wheel Drive vehicles, remove the six screws from the fuel pump bracket. On All-Trac 4-Wheel Drive vehicles, there are seven screws to remove.
- Withdraw the fuel pump bracket from the fuel tank. Remove the gasket from the fuel tank and discard it.
- Remove the two nuts that hold the pump to the bracket and disconnect the wires from the fuel pump.
- Pull the bracket from the bottom of the fuel pump.
- Disconnect the fuel hose (discharge) from the fuel pump.
- Remove the fuel filter rubber cushion and clip. Remove the filter from the pump.
- Install the fuel filter and secure with the clip. Install the rubber cushion.
- Connect the fuel hose to the fuel pump.
- Install the rubber cushion to the bottom of the fuel pump.
- Push the bottom of the fuel pump and the rubber cushion into the fuel pump bracket.
- Using a new gasket, place the bracket onto the fuel tank.
- Install the bracket retaining screws and tighten to 35 inch lbs. (4 Nm).
- Install the fuel tank.
- Fill the fuel tank and check for leaks.
- Connect the negative battery cable.
See Figure 6
Be sure this procedure is done in a well ventilated area.
- Disconnect the negative battery cable.
- Relieve the fuel pressure.
- Remove the rear seat cushion.
- Remove the floor service hole cover.
- Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there.
- Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
- Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet
pipe from the pump bracket.
- Remove the pump bracket attaching screws.
- Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
- Remove the nut and spring washer, then disconnect the wires from the pump bracket.
- Remove the sending unit attaching screws, then remove the unit from the bracket.
- Pull the lower side of the fuel pump from the bracket.
- Unplug the connector to the fuel pump.
- Disconnect the hose from the pump.
- Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
- Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
- When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
- Install the pump filter using a new clip. Install the rubber cushion under the filter.
- Connect the outlet hose to the pump, then attach the pump to the bracket and tighten to 22-25 ft. lbs. (29-34 Nm).
- Engage the connector to the fuel pump.
- Install the fuel sending unit to the pump bracket.
- Install the fuel pump and bracket assembly onto the tank. Use new gaskets. Tighten the pump bracket retaining screws to 34 inch lbs. (4 Nm).
- Connect the return hoses to the pump bracket.
- Install the service hole cover, then the engage the fuel pump and sending unit connector.
- Install the rear seat cushion.
- Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.
Fuel Pump Operation
EXCEPT 1MZ-FE ENGINES
Since the fuel pump is concealed within the tank, it is difficult to test directly at the pump. It is possible to test the pump from under the hood, listening for pump function and feeling the fuel delivery lines for the build-up of pressure.
- Turn the ignition switch ON , but do not start the engine.
- Using a jumper wire, short both terminals of the fuel pump check connector. The check connector is located near the air cleaner. Connect the terminals labeled FP and +B . Special service connector 09843-18020 or equivalent can be used to perform this test.
- Check that there is pressure in the hose running to the delivery pipe. You should hear fuel pressure noise and possibly hear the pump at the rear of the car.
If the fuel pump failed to function, it may indicate a faulty pump, but before removing the fuel pump, check the following items within the pump system:
- All fusible links
- All fuses (EFI-15A and IGN-7.5A)
- EFI main relay
- Fuel pump
- Circuit opening relay
- All wiring connections and grounds.
- Turn the ignition to OFF .
- Remove the jumper wire.
- If there is no fuel pump pressure and an inspection of the related electrical components does not reveal a malfunction, replace the fuel pump.
To check the resistance of the pump:
- Connect the positive and negative leads from the battery to the fuel pump harness.
- Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance should be 0.2-0.3 ohms at 68