Toyota Corolla 1988-1997 Repair Guide

Electric Fuel Pump

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REMOVAL & INSTALLATION



The electric fuel pump is contained within the fuel tank. On 1988-92 models, it is necessary to remove the fuel tank from the vehicle in order to reach the pump. On 1993-97 models, the fuel pump can be accessed by removing the rear seat cushion and service hole cover.

1988-92 Models

See Figures 1, 2, 3 and 4



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the electric fuel pump

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.

  1. Disconnect the negative battery cable and relieve the fuel pressure. Remove the filler cap.
  2.  
  3. Remove the fuel tank from the vehicle.
  4.  
  5. Remove the fuel pump bracket attaching screws, then remove the fuel pump/bracket assembly from the tank.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the bolts retaining the pump bracket to the fuel tank

  1. Pull the lower side of the fuel pump from the bracket.
  2.  
  3. Remove the nuts attaching the wires to the fuel pump.
  4.  
  5. Disconnect the hose from the pump.
  6.  
  7. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
  8.  



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Fig. Fig. 3: Pull off the lower portion of the pump from the bracket



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Fig. Fig. 4: If necessary, remove the clip and pull out the filter to replace it

  1. While the tank is out and disassembled, inspect it for any signs of rust, leakage or metal damage. If any problem is found, replace the tank.
  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. Install the pump filter using a new clip. Install the rubber cushion under the filter.
  2.  
  3. Connect the outlet hose to the pump, then attach the pump to the bracket.
  4.  
  5. Connect the wires to the fuel pump with the nuts.
  6.  
  7. Install the fuel pump and bracket assembly onto the tank. Use new gaskets.
  8.  
  9. Install the fuel tank.
  10.  
  11. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.
  12.  

1993-97 Models

See Figures 5, 6, 7 and 8



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Fig. Fig. 5: Exploded view of the fuel pump components

  1. Disconnect the negative battery cable.
  2.  


CAUTION
On models with an airbag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work. Refer to Drive Train for all air bag warnings.

  1. Relieve the fuel pressure.
  2.  
  3. Remove the rear seat cushion.
  4.  
  5. Remove the floor service hole cover.
  6.  



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Fig. Fig. 6: Remove the 4 service hole cover retaining screws

  1. Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there.
  2.  
  3. Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
  4.  
  5. Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet pipe from the pump bracket.
  6.  



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Fig. Fig. 7: Disconnect the outlet pipe from the pump bracket

  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.  
  5. Remove the nut and spring washer, then disconnect the wires from the pump bracket.
  6.  
  7. Remove the sending unit attaching screws, then remove the unit from the bracket.
  8.  



Click image to see an enlarged view

Fig. Fig. 8: Pull the pump bracket with pump attached from the tank

  1. Pull the lower side of the fuel pump from the bracket.
  2.  
  3. Unplug the connector to the fuel pump.
  4.  
  5. Disconnect the hose from the pump.
  6.  
  7. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
  8.  
  9. 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.
  10.  
  11. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
  12.  

To install:
  1. Install the pump filter using a new clip. Install the rubber cushion under the filter.
  2.  
  3. Connect the outlet hose to the pump, then attach the pump to the bracket and tighten to 22-25 ft. lbs. (29-34 Nm).
  4.  
  5. Engage the connector to the fuel pump.
  6.  
  7. Install the fuel sending unit to the pump bracket.
  8.  
  9. 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).
  10.  
  11. Connect the return hoses to the pump bracket.
  12.  
  13. Install the service hole cover, then the engage the fuel pump and sending unit connector.
  14.  
  15. Install the rear seat cushion.
  16.  
  17. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.
  18.  

TESTING



On-Vehicle Inspection

See Figures 9 and 10

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.

  1. Turn the ignition switch ON , but do not start the engine.
  2.  
  3. 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 .
  4.  



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Fig. Fig. 9: 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.  



Click image to see an enlarged view

Fig. Fig. 10: 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 (EFI-15amp and IGN-10.0amp)
    4.  
    5. H- fuse (AM2 30A)
    6.  
    7. EFI main relay
    8.  
    9. Fuel pump
    10.  
    11. Circuit opening relay
    12.  
    13. All wiring connections and grounds.
    14.  

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

Fuel Pressure

See Figure 11

  1. Check that the battery voltage is approximately 12 volts.
  2.  
  3. Disconnect the negative battery cable.
  4.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the hose from the fuel filter outlet.
  4.  
  5. Connect the hose and a fuel pressure gauge to the fuel filter outlet with three new gaskets and the union bolt.
  6.  



Click image to see an enlarged view

Fig. Fig. 11: Fuel pressure can be checked using an inexpensive pressure/vacuum gauge

  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 check connector.
  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.  
  11. 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.  

  12.  
  13. After checking the fuel pressure, turn the ignition OFF and remove the jumper wire from the check connector.
  14.  
  15. Disconnect the negative battery cable.
  16.  
  17. Relieve the fuel system pressure and remove the pressure gauge.
  18.  
  19. Connect the hose to the fuel filter outlet using new gaskets.
  20.  
  21. Wipe any fuel spillage.
  22.  
  23. Connect the negative battery cable, then start the engine and check for leaks.
  24.  

 
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