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 relieve the pressure may result in fire and/or serious injury.

REMOVAL & INSTALLATION



1FZ-FE Engine

See Figures 1 through 7

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rear seats of the vehicle.
  4.  



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Fig. Fig. 1: The rear seats must be removed to access the fuel pump and sending unit

  1. Remove the scuff plate, side garnish and step plate.
  2.  
  3. Remove the floor mats.
  4.  
  5. Remove the floor service hole cover.
  6.  



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Fig. Fig. 2: Loosen and remove the three service hole mounting screws

  1. Disconnect the fuel pipe and hose from the fuel pump bracket. Disconnect the pump and sensor gauge connection as follows:
    1. Remove the union bolt and gaskets, then disconnect the outer pipe from the pump bracket.
    2.  
    3. Detach the return hose from the pump bracket.
    4.  

  2.  



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Fig. Fig. 3: Remove the union bolt and gaskets, then disconnect the outlet pipe

  1. Remove the pump bracket assembly from the gas tank. Discard of the gasket from the pump bracket. Be careful not to bend the arm of the sender gauge.
  2.  



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Fig. Fig. 4: Remove the 8 bolts holding the fuel pump bracket to the gas tank



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Fig. Fig. 5: There are many parts holding the pump, filter and sender to the bracket

  1. Pull off the lower side of the pump from the pump bracket. Disconnect the pump wiring, then disconnect the fuel hose from the pump. This should release the pump from the unit.
  2.  



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Fig. Fig. 6: Pull the pump in an outward motion from the lower side of the bracket

  1. With the aid of a flat-bladed tool, remove the clip retaining the filter to the pump. This will allow the filter to slide off the pump.
  2.  



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Fig. Fig. 7: Carefully release the small C-clip from the filter

To install:
  1. Attach filter with the C-clip onto the pump.
  2.  
  3. Push the lower half of the pump into the bracket and attach the wiring. Connect the fuel hose to the pump.
  4.  
  5. With all of the pump parts in place on the bracket, slide the unit into the gas tank with a new gasket. Tighten to 35 inch lbs. (4 Nm).
  6.  
  7. Attach the union bolt with new gaskets along with the outlet pipe to the bracket. Tighten to 22 ft. lbs. (29 Nm).
  8.  
  9. Double check that all hoses are secure and that all wiring is intact, then install the service hole cover.
  10.  
  11. Install the floor mats, step plate, side garnish and scuff plate.
  12.  
  13. Install the rear seats, tighten to 29 ft. lbs. (39 Nm).
  14.  
  15. Start the vehicle and check for leaks.
  16.  

5VZ-FE Engine
  1. Remove the fuel tank.
  2.  
  3. Remove the fuel pump bracket or assembly from the tank. Disconnect the pump wiring from the clamp as follows:
    1. Remove the 8 mounting bolts and pull the bracket assembly out of the tank.
    2.  
    3. Remove and discard of the gasket on the pump bracket.
    4.  

  4.  
  5. Pull off the lower side of the pump from the pump bracket. Disconnect the pump wiring, then disconnect the fuel hose from the pump. This should release the pump from the unit.
  6.  
  7. With the aid of a flat-bladed tool, remove the clip retaining the filter to the pump. This will allow the filter to slide off the pump.
  8.  

To install:
  1. Attach filter with the C-clip onto the pump.
  2.  
  3. Push the lower half of the pump into the bracket and attach the wiring. Connect the fuel hose to the pump.
  4.  
  5. With all of the pump parts in place on the bracket, slide the unit into the gas tank with a new gasket. Tighten to 35 inch lbs. (4 Nm).
  6.  
  7. Install the fuel tank.
  8.  
  9. Start the vehicle and check for leaks.
  10.  

Testing



1FZ-FE Engine
1993-95 MODELS

See Figures 8 and 9

  1. Disconnect the battery cables, negative first. Remove the battery from the vehicle.
  2.  
  3. Remove the rear seats.
  4.  
  5. Remove the scuff plate, side garnish, step plate and carpet mats.
  6.  
  7. Remove the floor service hole cover.
  8.  
  9. Disconnect the fuel pump and sender gauge connector.
  10.  
  11. Check the resistance with the aside of an ohmmeter on terminals 5 and 6. The reading should be 0.2-3.0 ohms at 68°F (20°C). If the reading is not within specifications, replace the pump.
  12.  



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Fig. Fig. 8: Measure the resistance across terminals 5 and 6 of the fuel tank sender

  1. To inspect the pump operation, connect the positive lead from the battery to terminal 6 of the connector. Attach the negative lead to terminal 5, then check how the pump operates.
  2.  



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Fig. Fig. 9: Use a 12V battery to energize the fuel tank sender by placing the positive lead to terminal 6 and the negative lead to terminal 5

These tests must be performed quickly (within 10 seconds) to prevent the coil from burning out. Keep the pump away from the battery and always perform switching at the battery side.

  1. Reconnect the pump and sender gauge wiring.
  2.  
  3. Reinstall the floor service hole cover, floor mats, step plate, side garnish and scuff plates.
  4.  
  5. Install the rear seats, tighten to 29 ft. lbs. (39 Nm).
  6.  
  7. Reconnect the negative battery cable.
  8.  

1996 MODELS

See Figure 10

  1. Check the fuel pump operation as follows:
    1. Remove the fuse cover on the instrument panel.
    2.  
    3. Connect the Toyota hand-held tester or its equivalent scan tool to the 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:

      Fusible links (MAIN 2.0L, AM2 0.3P)
       
      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.  




Click image to see an enlarged view

Fig. Fig. 10: Toyota special service tools for most fuel injected engines

  1. Check the fuel pressure as follows:
    1. Check the battery positive voltage is above 12 volts.
    2.  
    3. Disconnect the negative cable from the battery.
    4.  
    5. Wrap a shop towel around the delivery pipe, then slowly loosen the union bolt holding the fuel pipe to the delivery pipe and gasket.
    6.  
    7. 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).
    8.  
    9. Be sure to wipe off any spilled fuel.
    10.  
    11. Attach the Toyota hand-held tester or equivalent scan tool to the DLC3. Reconnect the negative cable to the battery.
    12.  
    13. Turn the ignition switch ON.
    14.  
    15. Measure the fuel pressure, it should read 38-44 psi (265-304 kPa).
    16.  
    17. If the pressure is too high, replace the pressure regulator.
    18.  
    19. If the pressure is too low, check the following:

      Fuel connections and hose
       
      Fuel pump
       
      Fuel filter
       
      Pressure regulator
       

    20.  
    21. Disconnect the tester from the DLC3.
    22.  
    23. Reinstall the fuse box cover on the instrument panel.
    24.  
    25. Start the engine.
    26.  
    27. Disconnect the vacuum sensing hose from the fuel pressure regulator, then plug the hose end.
    28.  
    29. Measure the pressure at idle, 38-44 psi (265-304 kPa).
    30.  
    31. Reconnect the vacuum sensing hose to the fuel pressure regulator.
    32.  
    33. Measure the pressure at idle, 31-37 psi (226-255 kPa). If the pressure is not as specified, check the fuel; pump, pressure regulator and/or injectors.
    34.  
    35. Stop the engine.
    36.  
    37. Check that the fuel pressure remains as specified for 5 minuets after the engine has stopped. 21 psi (147 kPa). If the pressure is not as specified, check the pump, pressure regulator and/or injectors.
    38.  
    39. 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.
    40.  
    41. Reinstall the fuel pipe with new gaskets and the union bolts, tighten the bolts to 22-25 ft. lbs. (29-34 Nm).
    42.  
    43. Reconnect the negative cable to the battery.
    44.  
    45. Check for fuel leaks.
    46.  

  2.  

5VZ-FE Engine

See Figure 10

  1. Check the fuel pump operation as follows:
    1. Remove the fuse cover on the instrument panel.
    2.  
    3. Connect the Toyota hand-held tester or its equivalent scan tool to the DLC3.
    4.  

  2.  

Do not start the engine.

    1. Turn the ignition switch ON and push the tester's 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:

      H-fuse (ALT 80)
       
      M-fuse (AM1 40A, 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 as follows:
    1. Be sure that the battery positive voltage is above 12V.
    2.  
    3. Disconnect the negative cable from the battery.
    4.  
    5. Remove the bolts, then disconnect the No. 2 timing belt cover.
    6.  
    7. Wrap a shop towel around the delivery pipe, then slowly loosen the union bolt holding the fuel pipe to the delivery pipe and gasket.
    8.  
    9. 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).
    10.  
    11. Be sure to wipe off any spilled fuel.
    12.  
    13. Attach the Toyota hand-held tester or equivalent scan tool to the DLC3. Reconnect the negative cable to the battery.
    14.  
    15. Start the engine.
    16.  
    17. Measure the fuel pressure, it should read 38-44 psi (265-304 kPa).
    18.  
    19. If the pressure is too high, replace the pressure regulator.
    20.  
    21. If the pressure is too low, check the following:

      Fuel connections and hoses
       
      Fuel pump
       
      Fuel filter
       
      Pressure regulator
       
      Vacuum Switching Valve (VSV) for fuel pressure control
       

    22.  
    23. Disconnect the tester from the DLC3.
    24.  
    25. If removed, install the No. 2 timing belt cover, tighten to 80 inch lbs. (9 Nm).
    26.  
    27. Start the engine.
    28.  
    29. Disconnect the vacuum sensing hose from the fuel pressure regulator, then plug the hose end.
    30.  
    31. Measure the pressure at idle, 38-44 psi (265-304 kPa).
    32.  
    33. Reconnect the vacuum, sensing hose to the fuel pressure regulator.
    34.  
    35. Measure the pressure at idle, 31-38 psi (226-265 kPa). If the pressure is not as specified, check the fuel; pump, pressure regulator and/or injectors.
    36.  
    37. Stop the engine.
    38.  
    39. 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.
    40.  
    41. 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.
    42.  
    43. Remove the other union bolt, 3 gaskets and fuel pipe from the delivery pipes.
    44.  
    45. Reinstall the fuel pipe with new gaskets and the union bolts, tighten the bolts to 22-25 ft. lbs. (29-34 Nm).
    46.  
    47. Reconnect the negative cable to the battery.
    48.  
    49. Check for leaks.
    50.  

  2.  

 
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