Toyota Celica 1994-1998 Repair Guide

Fuel Pump

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REMOVAL & INSTALLATION



See Figures 1 through 20

Before disconnecting fuel system lines, clean the fittings with a spray-type engine cleaner. Follow the instructions on the cleaner. Do not soak fuel system parts in liquid cleaning solvent.


CAUTION
The fuel injection system is under pressure. Release pressure slowly and contain spillage. Observe "no smoking/no open flame" precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.



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Fig. Fig. 1: View of the common electric fuel pump located under the rear seat

  1. Disconnect the negative battery cable.
  2.  



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Fig. Fig. 2: It is very important to disconnect the negative battery cable whenever removing components on the fuel system

  1. Remove the rear seat cushion. Refer to Body & Trim .
  2.  
  3. Unscrew the service hole cover.
  4.  



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Fig. Fig. 3: Remove the screws retaining the service hole cover



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Fig. Fig. 4: Only four screws hold the service hole cover into the gas tank



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Fig. Fig. 5: Lift the service cover up to access the unit

  1. Disconnect the electrical fuel pump wiring at the pump assembly. Check for any fuel leakage while in there.
  2.  



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Fig. Fig. 6: Disconnect the wiring for the sending unit ...

  1. Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
  2.  
  3. Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet pipe from the pump bracket.
  4.  

  1. Remove the pump bracket attaching screws.
  2.  
  3. Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
  4.  



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Fig. Fig. 7: ... then slide the hose clamps back ...



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Fig. Fig. 8: ... and remove the fuel hose to the sending unit



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Fig. Fig. 9: A line wrench (flare-nut) and back-up wrench will be necessary to separate the fuel lines

  1. Remove the nut and spring washer, then disconnect the wires from the pump bracket.
  2.  



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Fig. Fig. 10: Remove the sending unit retaining bolts securing it to the fuel tank



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Fig. Fig. 11: Lift the pump and sender assembly from the fuel tank



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Fig. Fig. 12: Inspect the gasket, a good seal is necessary for replacement



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Fig. Fig. 13: Exploded view of the fuel pump and sender assembly

  1. Remove the sending unit attaching screws, then pull the unit from the bracket. To disassemble:
    1. Remove the lead wire.
    2.  
    3. Pull the lower side of the fuel pump from the bracket.
    4.  
    5. Remove the rubber cushion from the pump.
    6.  
    7. Disconnect the hose from the pump and extract the pump.
    8.  
    9. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
    10.  
    11. To remove the sender, disconnect the wiring from the bracket and unscrew the sender. Remove the screws, connector support, connector and gasket.

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      Fig. Fig. 14: Disconnect the lead wire from the pump



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      Fig. Fig. 15: Pull out the lower side of the pump to extract from the bracket



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      Fig. Fig. 16: Remove the clip to separate the filter from the pump

    12.  

  2.  
  3. 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.
  4.  
  5. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
  6.  

To install:
  1. To assemble the pump:
    1. Secure and install a new gasket, connector and support with the screws.
    2.  
    3. Attach the sensor and secure the screws, connect the wiring to the pump bracket.
    4.  
    5. Install the pump filter using a new clip.
    6.  
    7. Connect the outlet hose to the pump.
    8.  
    9. Install the rubber cushion to the fuel pump. Push the lower side of the pump into place to secure on the bracket.
    10.  
    11. Engage the connector to the fuel pump.

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      Fig. Fig. 17: Attach the connector and support with two screws, then ...



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      Fig. Fig. 18: ... install the sender gage with two screws to the bracket



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      Fig. Fig. 19: Push the lower side of the pump into the bracket to secure

    12.  

  2.  
  3. Install the fuel sending unit to the pump bracket.
  4.  
  5. Install the fuel pump and bracket assembly onto the tank. Use new gaskets. Tighten the pump bracket retaining screws to 31 inch lbs. (3 Nm).
  6.  



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Fig. Fig. 20: Tighten all eight pump bracket retaining screws to secure the assembly to the fuel tank

  1. Connect the return hoses to the pump bracket.
  2.  
  3. Install the service hole cover, then the engage the fuel pump and sending unit connector.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.
  8.  
  9. Install the rear seat cushion.
  10.  

TESTING



On-Vehicle Inspection
1994-95 MODELS

See Figures 21, 22, 23 and 24

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.



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Fig. Fig. 21: Fuel pump system circuit-1994-95 models

  1. Turn the ignition switch ON , but do not start the engine.
  2.  



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Fig. Fig. 22: Turn the ignition switch to the ON position, but do not start the engine

  1. Using a jumper wire, short both terminals of the fuel pump check connector. The check connector is located near the master cylinder. Connect the terminals labeled FP and +B on the DLC1.
  2.  



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Fig. Fig. 23: Using a jumper wire, short both terminals of the fuel pump check connector

  1. 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.
  2.  



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Fig. Fig. 24: Feel the high pressure hose at the fuel filter for pressure

  1. 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:
    1. All fusible links
    2.  
    3. All fuses
    4.  
    5. H- fuse
    6.  
    7. EFI main relay
    8.  
    9. Fuel pump
    10.  
    11. All wiring connections and grounds.
    12.  

  2.  
  3. Turn the ignition to OFF .
  4.  
  5. Remove the jumper wire.
  6.  

1996-98 MODELS
  1. Turn the ignition switch to the ON position, but do not start the engine.
  2.  
  3. Connect the positive and negative leads from the battery to the fuel pump wiring.
  4.  
  5. Check that there is pressure in the hose from the fuel filter.
  6.  

At this point you will hear a noise from the rear of the vehicle indicating that the pump is functioning.

  1. If there is no pressure inspect the following:
    1. Fusible link
    2.  
    3. H-Fuse (Main 60A)
    4.  
    5. Fuses (EFI 15A, AM2 30A, ING 7.5A)
    6.  
    7. Circuit opening relay
    8.  
    9. EFI main relay
    10.  
    11. Fuel pump
    12.  
    13. Wiring connections
    14.  

  2.  
  3. Turn the ignition switch OFF .
  4.  

Fuel Pressure
1994-95 MODELS

See Figures 25 and 26

  1. Check that the battery voltage is approximately 12 volts.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Disconnect the hose from the fuel filter outlet.
  8.  
  9. Connect the hose and a fuel pressure gauge to the fuel filter outlet with three new gaskets and the union bolt. Tighten to 22 ft. lbs. (29 Nm).
  10.  



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Fig. Fig. 25: Place a pressure gauge to the fuel filter outlet as shown

  1. Wipe any spilled gasoline.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. Using a jumper wire, short terminals FP and +B of the DLC1.
  6.  
  7. Turn the ignition switch ON , but do not start the car.
  8.  
  9. The fuel pressure should read 38-44 psi (265-304 kPa).
  10.  



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Fig. Fig. 26: Using a fuel pressure gauge to test the fuel filter

  1. If the pressure is too high, the pressure regulator is probably defective. If it is too low, check for the following:
    1. Fuel hoses and connections for leaks or restrictions.
    2.  
    3. Defective fuel pump.
    4.  
    5. Clogged fuel filter.
    6.  
    7. Defective pressure regulator.
    8.  

  2.  
  3. After checking the fuel pressure, turn the ignition OFF and remove the jumper wire from the DLC1.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Relieve the fuel system pressure and remove the pressure gauge.
  8.  
  9. Connect the hose to the fuel filter outlet using new gaskets.
  10.  
  11. Wipe any fuel spillage.
  12.  
  13. Connect the negative battery cable, then start the engine and check for leaks.
  14.  

1996-98 MODELS
  1. Check that the battery voltage is above 12 volts.
  2.  
  3. Disconnect the negative battery cable.
  4.  


WARNING
Make sure you place a suitable container and shop rag under the fuel line to catch any split fuel. The slowly loosen the union bolt.

  1. Relieve the fuel system pressure.
  2.  
  3. Remove the union bolt and 2 gaskets, then disconnect the fuel inlet hose from the delivery pipe.
  4.  
  5. Connect the fuel inlet hose and a pressure gauge to the delivery pipe with 3 gaskets and the union bolt. Tighten the bolt to 22 ft. lbs. (29 Nm).
  6.  
  7. Wipe off any split fuel.
  8.  
  9. Turn the ignition switch to the ON position but do not start the engine.
  10.  
  11. Connect the positive and negative leads from the battery to the fuel pump wiring.
  12.  
  13. Reconnect the negative terminal cable to the battery.
  14.  
  15. Turn the ignition switch ON , but do not start the car.
  16.  
  17. Measure the fuel pressure. Pressure should be between 38-44 psi (265-304 kPa).
  18.  
  19. If the pressure is too high, replace the fuel pressure regulator. If the pressure is too low, check the following:
    1. Fuel hoses
    2.  
    3. Fuel pump
    4.  
    5. Fuel filter
    6.  
    7. Fuel pressure regulator
    8.  
    9. Injectors
    10.  

  20.  

 
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