Toyota Celica 1986-1993 Repair Guide

Fuel Pump

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The electric fuel pump circuit is controlled by the ECU either directly or through the main/circuit opening relays. Under normal conditions, the controller will not energize the fuel pump unless other signals such as cranking, air flow and ignition are received. The fuel pump can be energized through the diagnostic connector for testing.

REMOVAL & INSTALLATION




CAUTION
Failure to relieve fuel pressure before repairs or disassembly can cause serious personal injury and/or property damage. Fuel pressure is maintained within the fuel lines, even if the engine is off or has not been run in a period of time. This pressure must be safely relieved before any fuel-bearing line or component is loosened or removed. On vehicles equipped with inflatable restraints or air bag systems, wait at least 30 seconds after disconnecting the battery cable before performing any other work. The backup power will keep the restraint system energized for a period of time after the battery is disconnected. The fuel pump is located inside the fuel tank. Do not smoke or have any open flame in the work area when removing the fuel pump.



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Fig. Fig. 1 Fuel pump components2S-E and 3S-GE engines



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Fig. Fig. 2 Removing fuel pump bracket2S-E and 3S-GE engines



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Fig. Fig. 3 Removing fuel pump from fuel pump bracket2S-E and 3S-GE engines



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Fig. Fig. 4 Removing fuel pump filter from fuel pump2S-E and 3S-GE engines



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Fig. Fig. 5 Removing fuel pump3S-GTE engine



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Fig. Fig. 6 Fuel pump components3S-GTE engine

Except 4A-FE and 5S-FE Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Position a suitable waste container under the fuel tank and drain or siphon the fuel from the tank.
  4.  
  5. Remove the fuel tank.
  6.  
  7. Remove the screws from the fuel pump and bracket.
  8.  
  9. Withdraw the fuel pump bracket from the fuel tank. Remove the gasket from the fuel tank and discard it.
  10.  
  11. Remove the two nuts that hold the pump to the bracket and disconnect the wires from the fuel pump.
  12.  
  13. Pull the bracket from the bottom of the fuel pump.
  14.  
  15. Disconnect the fuel hose (discharge) from the fuel pump.
  16.  
  17. Remove the fuel filter rubber cushion and clip. Remove the filter from the pump.
  18.  

To install:

  1. Install the fuel filter and secure with the clip. Install the rubber cushion.
  2.  
  3. Connect the fuel hose to the fuel pump.
  4.  
  5. Install the rubber cushion to the bottom of the fuel pump.
  6.  
  7. Push the bottom of the fuel pump and the rubber cushion into the fuel pump bracket.
  8.  
  9. Using a new gasket, place the bracket onto the fuel tank.
  10.  
  11. Install the bracket and the pump retaining screws and torque to 26-30 inch lbs. (2.9-3.4 Nm).
  12.  
  13. Install the fuel tank.
  14.  
  15. Add fuel to the fuel tank and check for leaks.
  16.  
  17. Connect the negative battery cable.
  18.  

4A-FE and 5S-FE Engines
  1. Disconnect the negative battery cable, then release the fuel pressure.
  2.  
  3. Remove the rear seat cushion.
  4.  
  5. Remove the floor service hole cover, disconnecting the fuel pump connector.
  6.  
  7. Disconnect the fuel supply hose from the fuel pump bracket by removing the union bolt. Remove gaskets and return hose.
  8.  
  9. Remove the screws, then pull out the pump and bracket assembly.
  10.  
  11. Remove the nut and screws that hold the sender to the bracket and disconnect the wires from the fuel pump.
  12.  
  13. Pull the bracket from the bottom of the fuel pump.
  14.  
  15. Disconnect the fuel hose (discharge) from the fuel pump.
  16.  
  17. Remove the fuel filter rubber cushion and clip. Remove the filter from the pump.
  18.  

To install:

  1. Install the fuel filter and secure with the clip. Install the rubber cushion.
  2.  
  3. Connect the fuel hose to the fuel pump.
  4.  
  5. Install the rubber cushion to the bottom of the fuel pump.
  6.  
  7. Push the bottom of the fuel pump and the rubber cushion into the fuel pump bracket.
  8.  
  9. Using a new gasket, place the bracket onto the fuel tank.
  10.  
  11. Install the bracket and the pump retaining screws and torque to 26-30 inch lbs. (2.9-3.4 Nm).
  12.  
  13. Install the supply hose and torque the union bolt to 22 ft. lbs. (29 Nm).
  14.  
  15. Reverse the remaining procedures to complete installation.
  16.  
  17. Connect the negative battery terminal and check for fuel leaks.
  18.  



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Fig. Fig. 7 Removing fuel pump4A-FE and 5S-FE engines



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Fig. Fig. 8 Fuel pump components4A-FE and 5S-FE engines

TESTING



Fuel Pump Operation
  1. Remove the rubber cap from the fuel EFI check connector and short the +B and FP terminals with a jumper wire.
  2.  
  3. Turn the ignition switch to the On position, but don't start the engine.
  4.  
  5. Check that there is pressure in the hose to the fuel filter.
  6.  
  7. Remove the jumper wire and turn the ignition switch Off position.
  8.  
  9. If no pressure can be felt in the line, check the following components:
    1. Fusible links
    2.  
    3. Fuses
    4.  
    5. Fuel pump relay or EFI main relay
    6.  
    7. Wiring connections
    8.  
    9. Fuel pump resistor
    10.  
    11. Fuel pump or ECU
    12.  

  10.  
  11. If there is no fuel pump pressure and an inspection of the related electrical components does not reveal a malfunction, replace the fuel pump.
  12.  



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Fig. Fig. 9 Shorting terminals FP and +B of check connector for checking fuel pump operationCelica



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Fig. Fig. 1 0Checking fuel pump hose for vibration when checking fuel pump operation2S-E engine

Fuel Pump Pressure
  1. Disconnect the negative battery terminal and the cold start valve electrical connector. Place a suitable container or shop towel under the rear of the cold start valve delivery pipe.
  2.  
  3. Slowly loosen the union bolt of the cold start injector hose; remove the bolt and 2 gaskets from the cold start delivery pipe.
  4.  
  5. Install a gasket, a pressure gauge, another gasket and the union bolt to the delivery pipe, torquing to 13 ft. lbs. (18 Nm) on the 2S-E, 3S-FE, 3S-GE and 5S-FE engines, or to 22 ft. lbs. (29 Nm) on the 4A-FE and 3S-GTE engines.
  6.  
  7. Wipe up any excess gasoline, then reconnect the negative battery cable.
  8.  
  9. Connect the terminals on the fuel pump check connector (FP and +B); turn the ignition switch On . Read the fuel pressure on the gauge. Indicated pressure should be:

    3S-FE engine: 38-44 psi (265-304 kPa)
     
    4A-FE engine: 38-44 psi (265-304 kPa)
     
    5S-FE engine: 38-44 psi (265-304 kPa)
     
    2S-E engine: 33-38 psi (226-265 kPa)
     
    3S-GE engine: 33-38 psi (226-265 kPa)
     
    3S-GTE engine: 33-38 psi (226-265 kPa)
     

  10.  
  11. Remove the service wire from the check connector. Start the engine. Disconnect the vacuum sensing hose from the pressure regulator and pinch it off. Measure the fuel pressure at idle. The fuel pressure should be the same as the above readings.
  12.  
  13. If the fuel pressure is too high, replace the pressure regulator.
  14.  
  15. If the fuel pressure is low, check the following components:
    1. Fuel hoses and fuel connections
    2.  
    3. Fuel pump
    4.  
    5. Fuel filter
    6.  
    7. Pressure regulator
    8.  

  16.  
  17. Reconnect the vacuum sensing hose to the pressure regulator. Measure the fuel pressure at idle; correct pressure should be:

    3S-FE engine: 33-37 psi (226-255 kPa)
     
    5S-FE engine: 33-37 psi (226-255 kPa)
     
    4A-FE engine: 31-37 psi (206-255 kPa)
     
    2S-E engine: 27-31 psi (186-216 kPa)
     
    3S-GE engine: 27-31 psi (186-216 kPa)
     
    3S-GTE engine: 27-31 psi (186-216 kPa)
     

  18.  
  19. If there is incorrect fuel pressure, check the vacuum sensing hose and pressure regulator. Stop the engine. Check that the fuel pressure remains above 21 psi (147 kPa) for 5 minutes after the engine has been shut off.
  20.  
  21. If not within specifications, check the fuel pump, pressure regulator and or the injectors.
  22.  
  23. After checking the fuel pressure, disconnect the negative battery cable and carefully remove the pressure gauge; prevent gasoline from splashing.
  24.  
  25. Using new gaskets, reconnect the cold start injector hose to the delivery pipe.
  26.  
  27. Reconnect the negative battery cable. Check for fuel leakage.
  28.  



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Fig. Fig. 1 1Installing fuel pressure gauge2S-E and 3S-GE engines



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Fig. Fig. 1 2Installing fuel pressure gauge5S-FE engine



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Fig. Fig. 1 3Checking fuel pressure with fuel pressure regulator hose disconnected and plugged3S-FE, 3S-GE and 3S-GTE engines

 
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