Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Electric Fuel Pump

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All Toyota fuel-injected vehicles are equipped with an electric fuel pump. The pump is located inside the fuel tank. For a fuel injection system to work properly, the pump must develop pressures well above those of a mechanical fuel pump. This high pressure is maintained within the lines even when the engine is not running. Extreme caution must be used to safely release the pressurized fuel before any work is begun.


CAUTION
Always relieve the fuel pressure within the system before any work is begun on any fuel component. Failure to safely relive the pressure may result in fire and/or serious injury.

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Safely relieve the fuel pressure within the system. Drain the fuel from the tank, then remove the fuel tank.
  4.  



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Fig. Fig. 1: Unbolt the fuel pump bracket from the fuel tank

  1. Remove the pump retaining bolts, then pull the fuel pump bracket up and out of the fuel tank.
  2.  



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Fig. Fig. 2: The electric fuel pump has a filter; check it for any clogging or tears

  1. Remove the gasket from the bracket.
  2.  
  3. Remove the two nuts and then disconnect the wires at the fuel pump.
  4.  
  5. Pull the fuel pump out of the lower side of the bracket. Disconnect the pump from the fuel hose.
  6.  



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Fig. Fig. 3: The pump should can be pulled from the lower side of the bracket in most cases

  1. Remove the rubber cushion and the clip. Disconnect the fuel pump filter from the pump.
  2.  



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Fig. Fig. 4: The filter has a retaining clip; pry it off to separate the filter and pump

To install:
  1. Install the fuel pump filter to the pump.
  2.  
  3. Insert the outlet port of the fuel pump into the fuel hose.
  4.  
  5. Install the rubber cushion to the lower side of the fuel pump.
  6.  
  7. Push the lower side of the fuel pump (and the rubber cushion) into the pump bracket.
  8.  



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Fig. Fig. 5: Push the lower side of the pump into the bracket

  1. Using a new gasket, position the bracket on the fuel tank and then install and tighten the seven mounting bolts to 30-35 inch lbs. (3-4 Nm).
  2.  



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Fig. Fig. 6: Before tightening the mounting bolts, make sure the gasket is in place so there are no gaps

  1. Install the fuel tank.
  2.  
  3. Add gas to the fuel tank.
  4.  
  5. Start the engine, then check for any loose connections or leaks.
  6.  

TESTING



See Figure 7

1989-95 Models
  1. Turn the ignition switch to the ON position, but don't start the engine.
  2.  
  3. With a jumper wire, connect terminals B+ and FP of the Data Link Connector (DLC1). This should cause the fuel pump to run; check that there is pressure in the fuel return line from the pressure regulator. You should also hear fuel return noises.
  4.  



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Fig. Fig. 7: Toyota special service tools for most fuel injected engines

  1. Turn the ignition switch OFF and remove the jumper wire. If the fuel pump did not function or if there was no pressure in the line, check the fuses, links, EFI main relay, ECM and wiring connections.
  2.  

1996 Models
2RZ-FE AND 3RZ-FE ENGINE
  1. To check the fuel pump operation:
    1. Remove the fuse cover on the instrument panel.
    2.  
    3. Connect the Toyota hand-held tester or its equivalent scan tool to the Data Link Connector (DLC3).
    4.  

  2.  

Do not start the engine.

    1. Turn the ignition switch ON and push the tester main switch on.
    2.  
    3. On the Toyota tester select the active test mode.
    4.  
    5. Refer to the tester instructions for further details.
    6.  
    7. If you do not have a Toyota hand-held tester, connect the positive and negative leads from the battery to the fuel pump connector.
    8.  
    9. Check that there is pressure in the fuel inlet hose from the fuel filter. If there is pressure, you will hear the sound of fuel flowing.
    10.  
    11. If there is no pressure, check the following:

      M-fuse (AM2 30A)
       
      Fuses (EFI 15A, IGN 7.5A)
       
      EFI main relay
       
      Fuel pump
       
      ECM
       
      Wiring connections
       

    12.  
    13. Turn the ignition switch to LOCK .
    14.  
    15. Disconnect the Toyota hand-held tester from the DLC3.
    16.  


  1. Check the fuel pressure.
    1. Disconnect the negative cable from the battery.
    2.  
    3. Wrap a shop towel around the delivery pipe, then slowly loosen the union bolt holding the fuel pipe to the delivery pipe and gasket.
    4.  
    5. Install the SST 09268-45012 (pressure gauge) or its equivalent to the delivery pipe with the two gaskets and the SST (union and union bolt). Tighten to 22 ft. lbs. (29 Nm).
    6.  
    7. Be sure to wipe off any spilled fuel.
    8.  
    9. Attach the Toyota hand-held tester or equivalent scan tool to the DLC3.
    10.  

  2.  

DO NOT start the engine!

    1. Turn the ignition switch ON and push the tester main switch on.
    2.  
    3. On the Toyota tester select the active test mode.
    4.  
    5. Refer to the tester instructions for further details.
    6.  
    7. If you do not have a Toyota hand-held tester, connect the positive and negative leads from the battery to the fuel pump connector.
    8.  
    9. Reconnect the negative battery cable.
    10.  
    11. Turn the ignition switch ON .
    12.  
    13. Measure the fuel pressure, it should read 38-44 psi (265-304 kPa).
    14.  
    15. If the pressure is too high, replace the pressure regulator.
    16.  
    17. If the pressure is too low, check the following:

      Fuel connections and hoses
       
      Fuel pump
       
      Fuel filter
       
      Pressure regulator
       
      Injectors
       

    18.  
    19. Disconnect the tester from the DLC3.
    20.  
    21. Start the engine.
    22.  
    23. Measure the fuel pressure at idle. It should read 31-37 psi (206-255 kPa). If the pressure is not as specified, check the sensing hose and pressure regulator.
    24.  
    25. Stop the engine.
    26.  
    27. Check that the fuel pressure remains at 21 psi (147 kPa) for 5 minutes after the engine has stopped. If the pressure is not as specified, check the pump, pressure regulator and/or injectors.
    28.  
    29. After checking the fuel pressure, disconnect the negative cable from the battery, then carefully remove the SST 09268-45012 or equivalent, to prevent gas from splashing.
    30.  
    31. Reconnect the fuel inlet pipe to the delivery pipe with new gaskets and the union bolt. Tighten to 22 ft. lbs. (29 Nm).
    32.  
    33. Reconnect the negative cable to the battery.
    34.  
    35. Check for fuel leaks.
    36.  


 
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