Toyota Tercel 1984-1994 Repair Guide

Electric Fuel Pump

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REMOVAL & INSTALLATION



See Figures 1 through 10

The electric fuel pump is contained within the fuel tank. On 1990 models, it is necessary to remove the fuel tank from the vehicle in order to reach the pump. On 1991-1994 models, the fuel pump can be accessed by removing the rear seat cushion and service hole cover.

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.

1990 Models
  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.  
  7. Pull the lower side of the fuel pump from the bracket.
  8.  
  9. Remove the nuts attaching the wires to the fuel pump.
  10.  
  11. Disconnect the hose from the pump.
  12.  
  13. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
  14.  
  15. 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.
  16.  
  17. 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.
  18.  
  19. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
  20.  

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.  



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Fig. Fig. 1: Fuel pump assembly on 1990 fuel injected models



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Fig. Fig. 2: Fuel pump/sending unit assembly on 1991-1994 models



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Fig. Fig. 3: On 1991-1994 models, the fuel pump assembly can be accessed after removing the rear seat and service hole cover



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Fig. Fig. 4: The fuel pump bracket assembly is usually secured to the fuel tank with screws



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Fig. Fig. 5: A special tool is needed to disconnect the outlet pipe from the pump bracket-1991-1994 models



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Fig. Fig. 6: Removing the fuel pump from the pump bracket on 1990 fuel injected models



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Fig. Fig. 7: Fuel cut-off valve removal on 1991-1994 models



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Fig. Fig. 8: The sending unit is secured to the pump bracket assembly on 1991-1994 models



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Fig. Fig. 9: Removing the fuel pump from the pump bracket assembly on 1991-1994 models



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Fig. Fig. 10: The pump filter retaining clip can be removed using a small screwdriver

1991-1994 Models
  1. Disconnect the negative battery cable and relieve the fuel pressure. Remove the filler cap.
  2.  
  3. Remove the rear seat cushion from the vehicle.
  4.  
  5. Unplug the fuel pump and sending unit connector.
  6.  
  7. Remove the service hole cover.
  8.  
  9. Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet pipe from the pump bracket.
  10.  
  11. Remove the pump bracket attaching screws.
  12.  
  13. Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
  14.  
  15. Remove the fuel cut-off valve from the bracket assembly.
  16.  
  17. Remove the nut and spring washer, then disconnect the wires from the pump bracket.
  18.  
  19. Remove the sending unit attaching screws, then remove the unit from the bracket.
  20.  
  21. Pull the lower side of the fuel pump from the bracket.
  22.  
  23. Unplug the connector to the fuel pump.
  24.  
  25. Disconnect the hose from the pump.
  26.  
  27. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
  28.  
  29. 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.
  30.  
  31. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
  32.  

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. Engage the connector to the fuel pump.
  6.  
  7. Install the fuel sending unit to the pump bracket.
  8.  
  9. Install the fuel cut-off valve to the fuel pump bracket with a new gasket.
  10.  
  11. Install the fuel pump and bracket assembly onto the tank. Use new gaskets.
  12.  
  13. Connect the return hoses to the pump bracket.
  14.  
  15. Install the service hole cover, then the engage the fuel pump and sending unit connector.
  16.  
  17. Install the rear seat cushion.
  18.  
  19. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.
  20.  

TESTING



See Figures 11 and 12

Pump Operation
  1. Turn the ignition switch ON , but do not start the motor.
  2.  
  3. Using a jumper wire, short terminals FP and +B of the check connector.
  4.  
  5. Feel that there is pressure in the hose running to the delivery pipe. You should hear the pump at the rear of the car.
  6.  
  7. Remove the jumper wire.
  8.  
  9. Turn the ignition to OFF . If the fuel pump failed to function, it may indicate a faulty pump, but before removing the pump, check the following items within the pump system:
    1. Fusible links
    2.  
    3. Fuses
    4.  
    5. Fuel injection main relay
    6.  
    7. Fuel pump circuit opening relay
    8.  
    9. All wiring connections and grounds
    10.  

  10.  



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Fig. Fig. 11: Fuel pump test terminals of the check connector



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Fig. Fig. 12: The fuel pressure gauge should be connected to the fuel filter outlet

Fuel Pressure

  1. Check that the battery voltage is approximately 12 volts.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Disconnect the hose from the fuel filter outlet.
  8.  
  9. Connect the hose and a fuel pressure gauge to the fuel filter outlet with three new gaskets and the union bolt.
  10.  
  11. Wipe any spilled gasoline.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Using a jumper wire, short terminals FP and +B of the check connector.
  16.  
  17. Turn the ignition switch ON , but do not start the car.
  18.  
  19. The fuel pressure should read 38-44 psi (265-304 kpa).
  20.  
  21. 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.  

  22.  
  23. After checking the fuel pressure, turn the ignition OFF and remove the jumper wire from the check connector.
  24.  
  25. Disconnect the negative battery cable.
  26.  
  27. Relieve the fuel system pressure and remove the pressure gauge.
  28.  
  29. Connect the hose to the fuel filter outlet using new gaskets.
  30.  
  31. Wipe any fuel spillage.
  32.  
  33. Connect the negative battery cable, then start the engine and check for leaks.
  34.  

 
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