Toyota Celica, Corolla, ECHO & MR2 1999-05

Fuel Pump

Print

Removal & Installation



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.



Click image to see an enlarged view

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

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. 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 Section 10.
  2.  
  3. Unscrew the service hole cover.
  4.  



Click image to see an enlarged view

Fig. Remove the screws retaining the service hole cover



Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. 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.  



Click image to see an enlarged view

Fig. 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.  
  5. Remove the pump bracket attaching screws.
  6.  
  7. Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
  8.  



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. 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.  



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. 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.

      Click image to see an enlarged view

      Fig. Disconnect the lead wire from the pump



      Click image to see an enlarged view

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



      Click image to see an enlarged view

      Fig. 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.

      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

      Fig. 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.  



Click image to see an enlarged view

Fig. 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.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding

    Click image to see an enlarged view

    Fig. Pull the pump off the sender unit; the filter is still attached to the pump

     
    Rear seat cushion and floor service hole cover
     
    Access plate-to-fuel tank bolts, then pull out the plate/fuel pump assembly
     
    Fuel pump sender and fuel pump connector
     
    Outlet pipe from the fuel pump bracket
     
    Return hose from the pump bracket
     
    Fuel pump bracket assembly from the fuel tank
     
    Lower side of the fuel pump from the pump bracket
     
    Fuel pump connector
     
    Fuel hose from the fuel pump
     
    Rubber cushion from the pump
     
    Fuel filter from the pump by removing the small clip
     

  6.  

To install:

  1. Install or connect the following:

    New cushion to the fuel pump
     
    Fuel filter and new clip to the fuel pump
     
    Fuel hose to the fuel pump, fuel pump connector and fuel pump to the bracket
     
    Fuel pump bracket assembly to the fuel tank using a new gasket. Bolts: 30 inch lbs. (3 Nm).
     
    Fuel return hose and the fuel outlet pipe to the fuel pump bracket
     
    Fuel pump and fuel pump sender connector
     
    Fuel tank
     
    Negative battery cable
     
    Floor service hole cover and rear seat cushion
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding

    Click image to see an enlarged view

    Fig. Pull the pump off the sender unit; the filter is still attached to the pump

     
    Rear seat cushion and floor service hole cover
     
    Access plate-to-fuel tank bolts, then pull out the plate/fuel pump assembly
     
    Fuel pump sender and fuel pump connector
     
    Outlet pipe from the fuel pump bracket
     
    Return hose from the pump bracket
     
    Fuel pump bracket assembly from the fuel tank
     
    Lower side of the fuel pump from the pump bracket
     
    Fuel pump connector
     
    Fuel hose from the fuel pump
     
    Rubber cushion from the pump
     
    Fuel filter from the pump by removing the small clip
     

  6.  

To install:

  1. Install or connect the following:

    New cushion to the fuel pump
     
    Fuel filter and new clip to the fuel pump
     
    Fuel hose to the fuel pump, fuel pump connector and fuel pump to the bracket
     
    Fuel pump bracket assembly to the fuel tank using a new gasket. Bolts: 30 inch lbs. (3 Nm).
     
    Fuel return hose and the fuel outlet pipe to the fuel pump bracket
     
    Fuel pump and fuel pump sender connector
     
    Fuel tank
     
    Negative battery cable
     
    Floor service hole cover and rear seat cushion
     

  2.  



Click image to see an enlarged view

Fig. Fuel pump removal-Echo

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
     
    Rear seat cushion
     
    Floor service hole cover
     
    Electrical connector at the fuel pump assembly
     
    Fuel outlet pipe from the fuel pump bracket
     
    Return hose from the fuel pump bracket.
     
    Fuel pump set plate from the fuel tank by removing the 8 bolts
     
    Fuel pump from the fuel bracket
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump to the fuel tank. Bolts: 35 inch lbs. (4 Nm).
     
    Return hose to the fuel pump bracket
     
    Outlet pipe to the fuel pump bracket. Tighten to 21 ft. lbs. (28 Nm).
     
    Service hole cover to the fuel tank
     
    Fuel pump connector
     
    Rear seat cushion
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Luggage compartment box
     
    Service access panel
     
    Fuel pump and gauge harness connector
     
    Vapor pressure sensor harness connector
     
    Fuel main tube
     
    Emissions tube
     
    Fuel pump module
     

  4.  

To install:

  1. Install or connect the following:

    Fuel pump module. Tighten the bolts to 30 inch lbs. (3.4 Nm).
     
    Emissions tube
     
    Fuel main tube
     
    Vapor pressure sensor harness connector
     
    Fuel pump and gauge harness connector
     
    Service access panel
     
    Luggage compartment box
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

Testing



On-Vehicle Inspection
  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.  

Pressure Testing
  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 two 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 three 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.  

 
label.common.footer.alt.autozoneLogo