Toyota Pick-ups, Land Cruiser, and 4 Runner 1997-00

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.

A quick test for pump operation is to remove the gas cap and listen at the fuel filler opening. Have an assistant turn the ignition switch to the ON position. It should be possible to hear the pump run. More information can be found under "Testing" in this section.


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



Except Land Cruiser


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Fig. Fuel gauge sending unit and fuel pump arrangement2000 Tundra shown, other trucks similar

  1. Remove the fuel tank from the vehicle. For additional information, please refer to the following topic(s): Fuel Tank Removal and Installation.
  2.  
  3. Remove the fuel pump bracket or assembly from the tank. Disconnect the pump wiring from the clamp as follows:
    1. Remove the eight mounting bolts and pull the bracket assembly out of the tank.
    2.  
    3. Remove and discard the gasket on the pump bracket.
    4.  

  4.  
  5. Pull the lower side of the pump off of the pump bracket. Disconnect the pump wiring, and 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.  

Land Cruiser

CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do NOT allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry-chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect the negative battery cable.
  2.  
  3. The Land Cruiser has a removable plate in the rear floor, under the carpet, to access the fuel pump. There may be some variation in this procedure as the interior trim components vary between model years. The following should suffice for Land Cruiser fuel pump removal.
  4.  
  5. Remove the rear seats from the Land Cruiser to get to the access plate. The seats use retainer brackets and bolts that go through the brackets and thread into the floorpan. The bolt heads may be covered by a trim cap that can be pried off.
  6.  



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Fig. The rear seats must be removed to access the fuel pump and sending unitLand Cruiser



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Fig. Loosen and remove the service access panel mounting screwsLand Cruiser



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Fig. On 1997 models, remove the union bolt and gaskets, then disconnect the fuel outlet pipeLand Cruiser



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Fig. On 1998 and newer models, quick-connect fittings are used with clips to retain the fuel lines to the fuel pump assemblyLand Cruiser

  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.  
  7. Disconnect the fuel pipe and hose from the fuel pump bracket. Disconnect the pump and sensor gauge connection as follows:
    1. Fuel injection systems use two fuel lines. One is pressure to the engine; the other is excess fuel being returned to the tank. Tag the hoses for identification so they can be returned to their proper locations.
    2.  
    3. The 1997 Land Cruiser uses union bolts to retain the fuel lines at the fuel pump. Remove the bolts and separate the fittings.
    4.  
    5. 1998 and newer Land Cruisers no longer use the union bolt and gaskets found in earlier models. Quick-connect connectors are used to secure the lines at the fuel pump. They use horseshoe-shaped clips to retain the hoses to the fuel pump connections. Clean the top of the fuel pump where the connectors are located with a soft bristle brush (paint brush) to clear away dirt and road debris to keep from contaminating the fuel tank.
    6.  
    7. Spread the horseshoe-shaped clips. Toyota specifically advises against using tools to open the clips. Spread the clips slightly and detach both the fuel feed and the fuel return lines. It may be helpful to turn the nylon fuel lines by hand to free them for removal. Toyota recommends plugging the fuel lines to keep out dirt.
    8.  

  8.  
  9. Remove the pump bracket assembly from the gas tank. There should be eight small screws. Discard the gasket from the pump bracket. Be careful not to bend the arm of the sender gauge.
  10.  



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Fig. Remove the eight bolts holding the fuel pump bracket to the gas tank



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



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



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Fig. Carefully release the small C-clip from the in-tank fuel strainer

  1. Pull the lower side of the pump from the pump bracket. Disconnect the pump wiring, and then disconnect the fuel hose from the pump. This should release the pump from the unit.
  2.  
  3. With the aid of a flat-bladed tool, remove the clip retaining the in-tank fuel strainer to the pump, allowing the strainer to slide off the pump.
  4.  

To install:

  1. Attach a replacement strainer 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 the eight retaining screws to 35 inch lbs. (4 Nm).
  6.  
  7. On 1997 Land Cruisers, attach the union bolt with new gaskets along with the outlet pipe to the bracket. Tighten to 22 ft. lbs. (29 Nm).
  8.  
  9. On 199800 Land Cruisers, before installing the quick-connect clips, make sure no dirt has gotten between the nylon tube and the top of the fuel pump mounting plate. Attach the fuel tube connectors to the ports and insert the clips until you hear a click. After connection, pull on the clips to make sure they are installed securely.
  10.  
  11. Connect the fuel pump wiring.
  12.  
  13. Connect the negative battery cable. Turn the ignition switch to the ON position to pressurize the system. Check for leaks.
  14.  
  15. When satisfied with the installation, double-check that all hoses are secure and that all wiring is intact, then install the service hole cover.
  16.  
  17. Install the floor mats, step plate, side garnish and scuff plate.
  18.  
  19. Install the rear seats; tighten to 29 ft. lbs. (39 Nm).
  20.  
  21. Start the vehicle and check again for leaks.
  22.  

TESTING



Except Land Cruiser and Tundra

Check the fuel pump operation using the following procedure.

  1. Connect a scan tool to the DLC3 diagnostic connector located under the instrument panel
  2.  

Do NOT start the engine.

  1. Turn the scan tool on and follow the prompts to turn on the fuel pump from the scan tool.
    1. If you Do NOT have a scan tool, connect the positive and negative leads from a 12V battery to the fuel pump connector.
    2.  

  2.  
  3. 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.
  4.  
  5. If there is no pressure, check the following:

    H-fuse
     
    M-fuse
     
    Fuses
     
    EFI main relay
     
    Fuel pump
     
    ECM
     
    Wiring connections
     

  6.  
  7. Turn the ignition switch to LOCK .
  8.  
  9. Disconnect the scan tool from the DLC3.
  10.  

Check the fuel pressure using the following procedure.

  1. Be sure that the battery voltage is above 12 volts.
  2.  
  3. Disconnect the negative cable from the battery.
  4.  
  5. Remove the bolts, and then disconnect the No. 2 timing belt cover.
  6.  
  7. Wrap a shop towel around the delivery pipe, and then slowly loosen the union bolt holding the fuel pipe to the delivery pipe and gasket.
  8.  
  9. Install a fuel pressure gauge with adapters to accommodate the fuel line (delivery pipe). Use the two gaskets and the union and union bolt. Tighten to 22 ft. lbs. (29 Nm).
  10.  
  11. Be sure to wipe up any spilled fuel.
  12.  
  13. Reconnect the negative cable to the battery.
  14.  
  15. Start the engine.
  16.  
  17. Measure the fuel pressure; it should read 3844 psi.
  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. If removed, install the No. 2 timing belt cover, tighten to 80 inch lbs. (9 Nm).
  24.  
  25. Start the engine.
  26.  
  27. Disconnect the vacuum line from the fuel pressure regulator, then plug the hose end.
  28.  
  29. The fuel pressure at idle should be 3844 psi.
  30.  
  31. Reconnect the vacuum line to the fuel pressure regulator.
  32.  
  33. The fuel pressure at idle should now be 3138 psi. 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 system holds pressure at 21 psi for five minutes after the engine has stopped. 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 fuel pressure gauge and adapters. Use care to prevent gasoline spills.
  40.  
  41. Connect the vehicle's fuel line using new gaskets. Tighten the bolts to 2225 ft. lbs. (2934 Nm).
  42.  
  43. Reconnect the negative cable to the battery.
  44.  
  45. Start the engine and check for leaks.
  46.  



Click image to see an enlarged view

Fig. Checking the fuel pump with an ohmmeter and also applying 12 volts to the connector2000 4Runner with 5VZ-FE engine shown, 2RZ-FE and 3RZ-FE engines similar

To check the fuel pump electrically, use the following procedure.

  1. Remove the fuel tank from the vehicle using all precautions when working around gasoline.
  2.  
  3. At the fuel pump connector. Use an ohmmeter to check the pump's resistance. At room temperature, the resistance should be 0.23.0 ohms. If not, replace the fuel pump assembly.
  4.  
  5. A piece of rubber hose should be installed on the pump outlet and placed in an approved gasoline container.
  6.  
  7. Perform this test quickly, limiting the run time to 10 seconds to keep from burning out the pump coil. Keep the pump as far away as possible from the battery and always do the switching at the battery side.
  8.  
  9. Connect a jumper wire from the positive terminal of a 12-volt battery to terminal 4 of the connector. Connect a jumper wire from the negative terminal of a 12-volt battery to terminal 5 of the connector. The pump should run.
  10.  
  11. If the pump does not meet these tests, replace the fuel pump assembly.
  12.  

Land Cruiser


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Fig. Activate the fuel pump using a scan tool. Check for pulsations at the fuel inlet line1997 Land Cruiser with 1FZ-FE engine shown; others similar



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Fig. Activate the fuel pump using a scan tool. Check that the pulsation damper screw rises up when the fuel pump operates1998 Land Cruiser with 2UZ-FE engine



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Fig. Check fuel pump pressure with a gauge. Test with the fuel pressure regulator hose attached, then disconnected1997 Land Cruiser with 1FZ-FE engine shown, others similar



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Fig. Checking the fuel pump with an ohmmeter and also applying 12 volts to the connector1997 Land Cruiser with 1FZ-FE engine shown



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Fig. Checking the fuel pump with an ohmmeter and also applying 12 volts to the connector1998 Land Cruiser with 2UZ-FE engine shown



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Fig. When troubleshooting a fuel pump problem, check the EFI Main Relay1997 Land Cruiser



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Fig. On 199800 Land Cruisers, check the EFI main relay when troubleshooting a fuel pump problem



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Fig. When troubleshooting a fuel pump problem, check the Fuel Pump Relay1997 Land Cruiser shown

Check the fuel pump operation using the following procedure.

  1. Remove the fuse cover on the instrument panel.
  2.  
  3. Connect a scan tool to the DLC3 diagnostic connector.
  4.  

Do NOT start the engine.

  1. Turn the ignition switch ON and activate the scan tool.
  2.  
  3. Locate and enable the scan tool's Test Fuel Pump function.
  4.  
  5. Refer to the scan tool's prompts and operator guide for further details.
  6.  
  7. If you do not have a scan tool, remove the rear seat and carpet as noted in the "Fuel Pump Removal" procedure. Remove the access cover and connect the positive and negative leads from a 12-volt power source (battery) to the fuel pump connector.
  8.  
  9. Check that there is pressure in the fuel inlet hose from the fuel filter. There are several ways to check for pressure. If there is pressure, you should be able to feel fuel pump pulsations in the fuel inlet line. You should also be able to hear the sound of fuel flowing. Sometimes an assistant listening at the fuel tank fill opening (fuel tank cap off) can verify the pump is running.
  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 the LOCK position.
  14.  
  15. Disconnect the scanner from the DLC3.
  16.  

Check the fuel system operating pressure using the following procedure.

  1. Check that the battery positive voltage is above 12 volts (battery is charged).
  2.  
  3. Disconnect the negative cable from the battery.
  4.  
  5. At the engine's fuel rail, wrap a shop towel around the delivery pipe, then slowly loosen the union bolt holding the fuel inlet pipe to the fuel rail.
  6.  
  7. Install a fuel pressure gauge with the necessary adapters to the fuel inlet pipe, using the two gaskets and the union and union bolt, as necessary. Tighten to 22 ft. lbs. (29 Nm). Wipe up any spilled fuel.
  8.  
  9. Attach a scan tool to the DLC3 diagnostic connector. Reconnect the negative cable to the battery.
  10.  
  11. Turn the ignition switch ON .
  12.  
  13. Measure the fuel pressure, it should read 3844 psi (265304 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
     

  18.  
  19. Disconnect the tester from the DLC3.
  20.  
  21. Reinstall the fuse box cover on the instrument panel.
  22.  
  23. Start the engine.
  24.  
  25. Disconnect and plug the vacuum hose from the fuel pressure regulator.
  26.  
  27. Measure the pressure at idle, 3844 psi (265304 kPa).
  28.  
  29. Reconnect the vacuum hose to the fuel pressure regulator.
  30.  
  31. Measure the pressure at idle, 3137 psi (226255 kPa). If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
  32.  
  33. Stop the engine.
  34.  
  35. Check that the fuel pressure holds at about 21 psi for five minutes, after engine shutdown. If the system doesn't hold pressure, check the pump, pressure regulator and/or injectors.
  36.  
  37. After checking the fuel pressure, disconnect the negative cable from the battery, then carefully remove the fuel pressure gauge and any adapters to prevent fuel spillage.
  38.  
  39. Reinstall the fuel pipe with new gaskets and tighten the union bolts to 2225 ft. lbs. (2934 Nm).
  40.  
  41. Reconnect the negative cable to the battery.
  42.  
  43. Check for fuel leaks.
  44.  

Tundra

To check the fuel pump operation, use the following procedure.

  1. Connect a scan tool to the under dash diagnostic connector DLC3.
  2.  
  3. Following the tool prompts, activate the fuel pump.
  4.  

Do NOT start the engine.

  1. Locate and check the pulsation damper. The center screw should rise up when the pump operates. If not, check:

    Fusible links
     
    Fuses
     
    EFI main relay
     
    Fuel pump
     
    ECM
     
    All related wiring connections
     

  2.  

To check the fuel pressure, use the following procedure.



Click image to see an enlarged view

Fig. Fuel pressure gauge installation arrangement2000 Tundra with 2UZ-FE engine



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Fig. Checking the fuel pump with an ohmmeter and also applying 12 volts to the connector2000 Tundra with 2UZ-FE engine

  1. Verify that the ignition switch is in the OFF position.
  2.  
  3. Verify that the battery is charged.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the front fuel line from the left side fuel rail.
  8.  
  9. Connect a fuel pressure gauge using the appropriate adapters.
  10.  
  11. Clean up any spilled gasoline.
  12.  
  13. Reconnect the negative battery terminal.
  14.  
  15. Connect a scan tool to the under dash diagnostic connector DLC3.
  16.  
  17. Following the tool prompts, activate the fuel pump.
    1. Fuel pressure should be 3844 psi.
    2.  
    3. If the pressure is too high, replace the fuel pressure regulator.
    4.  
    5. If the fuel pressure is too low, check the hoses and connections, fuel pump, fuel filter and fuel pressure regulator.
    6.  

  18.  
  19. Disconnect the scan tool from DLC3.
  20.  
  21. Start the engine and measure the fuel pressure at idle. Idle fuel pressure should be 3844 psi.
  22.  
  23. Stop the engine and verify that the system holds fuel pressure of 21 psi or more for five minutes.
    1. If the system does not hold pressure, check the fuel pump, pressure regulator and look for a leaking fuel injector.
    2.  

  24.  
  25. When all checks are done, disconnect the negative battery cable and remove the fuel pressure gauge and adapters.
  26.  
  27. Reconnect the vehicle's fuel line to the fuel rail.
  28.  
  29. Connect the negative battery cable, start the engine and check for leaks.
  30.  

To check the fuel pump electrically, use the following procedure.

  1. Remove the fuel tank from the vehicle using all precautions when working around gasoline.
  2.  
  3. At the fuel pump connector. Use an ohmmeter to check the pump's resistance. At room temperature, the resistance should be 0.23.0 ohms. If not, replace the fuel pump assembly.
  4.  
  5. A piece of rubber hose should be installed on the pump outlet and placed in an approved gasoline container.
  6.  
  7. Perform this test quickly and limit the run time to 10 seconds to keep from burning out the pump coil. Keep the pump as far away as possible from the battery and always do the switching at the battery side.
  8.  
  9. Connect a jumper wire from the positive terminal of a 12-volt battery to terminal 1 of the connector. Connect a jumper wire from the negative terminal of a 12-volt battery to terminal 2 of the connector. The pump should run.
  10.  
  11. If the pump does not meet these tests, replace the fuel pump assembly.
  12.  

 
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