Toyota Highlander 6 2001-06

Fuel Pump

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Removal & Installation



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

    Both rear seats
     
    Carpet
     
    Service hole cover
     
    Connector
     
    Joint clip and pull out the fuel tube
     
    Vent tube set plate
     
    Pump and gauge assembly
     

  6.  
  7. Installation is the reverse of removal.
  8.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the deck board assembly.
  6.  
  7. Remove the rear seats.
  8.  
  9. Remove the left side door scuff plate.
  10.  
  11. Remove the left side trim cover.
  12.  
  13. Remove the left rear seat side cover.
  14.  
  15. Remove the carpet.
  16.  
  17. Remove the rear floor service cover.
  18.  
  19. Disconnect the fuel pump wiring.
  20.  
  21. Disconnect the fuel hose.
  22.  
  23. Remove the fuel pump locking ring. Special tool 09808-14020 is available for this job.
  24.  
  25. Remove the pump assembly from the tank.

    Click image to see an enlarged view

    Fig. Lock ring positioning during installation-2004-05 Highlander

  26.  
  27. Installation is the reverse of removal. When installing the locking ring, tighten it first by hand, then, using the special tool turn the ring 1 1 / 2 turn. The triangle mark on the lockring must be positioned between the A and MAX marks on the fuel tank.
    WARNING
    No other type of tool should be used for this operation.

  28.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the center exhaust pipe.
  8.  
  9. Remove the front floor heat insulator No: 3.
  10.  
  11. Remove the fuel tank protector assembly.
  12.  
  13. Separate the parking brake assembly.
  14.  
  15. Disconnect the fuel tank wire.
  16.  
  17. Remove the charcoal canister protector and hose.
  18.  
  19. Disconnect the fuel tank main tube sub assembly.
  20.  
  21. Disconnect the breather lower tube and remove the fuel tank.
  22.  
  23. Disconnect all wiring and hoses from the pump.
  24.  
  25. Remove the pump cover bolts and remove the cover and pump.
  26.  

To install:

  1. Install the pump assembly, cover and bolts. Tighten the bolts to53 inch lbs. (6 Nm).
  2.  
  3. Install the fuel tank and tighten the strap bolts to 29 ft. lbs. (39 Nm).
  4.  
  5. Install the remaining components in the reverse order of removal.
  6.  

Hybrid
  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
     
    Center exhaust pipe assembly
     
    Front floor heat insulation
     
    Fuel tank skid plate
     
    Parking brake cable support
     
    Fuel tank electrical connection
     
    Charcoal canister protector and fuel hose
     
    Fuel tank main supply hose
     
    Fuel tank breather hose
     
    Fuel tank assembly
     

  6.  
  7. Remove the fuel pump assembly from the tank as follows:
    1. Disconnect the fuel pump connector.
    2.  
    3. Disconnect the clamp and vapor pressure sensor connector.
    4.  
    5. Remove the hose joint clip and clamp. Pull out the fuel hose.
    6.  
    7. Remove the mounting bolts and pull the fuel pump assembly from the tank.
    8.  

  8.  

To install:

  1. Install a the fuel pump assembly into the tank with a new gasket.
    NOTE
    Align the fuel tank vent tube set plate with the cutout on the fuel pump assembly.

  2.  
  3. Install the fuel connector plate and tighten the bolts to 53 inch lbs. (6 Nm).
  4.  
  5. The remainder of installation is the reverse order of removal.
  6.  
  7. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  8.  

 
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