Yaris 2007

Fuel Pump & Module

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Removal & Installation




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. Remove the rear seats and deck board.
  2.  
  3. Remove rear floor service hole cover:
    1. Remove the rear floor service hole cover.
    2.  
    3. Disconnect the fuel pump connector.
    4.  

  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Disconnect fuel tank main tube sub-assembly:
    1. Widen the tip of the tube joint clip and pull out the clip in the direction indicated by the arrow.
    2.  
    3. Disconnect the fuel tank main tube.
      NOTE
      Note the following:



      Keep the O-ring free of any foreign matter, as it becomes contaminated easily.
       
      Do not use any tools in this procedure.
       
      Do not forcefully bend or twist the tube.
       
      Put the tube in a plastic bag to prevent damage and contamination.
       
      If the fuel suction plate and tube are stuck together, pinch the tube and turn it carefully to disconnect them.
       
      Do not damage any clips. If a clip is damaged, replace it.

      Click image to see an enlarged view

      Fig. Disconnect fuel tank main tube sub-assembly

       

    4.  

  10.  
  11. Disconnect the fuel tank vent hose.

    Click image to see an enlarged view

    Fig. Disconnect the fuel tank vent hose

  12.  
  13. Using SST 09808-14020, remove the fuel pump gauge retainer.
    NOTE
    Align the claws of the fuel pump gauge retainer with the tips of SST.



    Click image to see an enlarged view

    Fig. Using SST 09808-14020, remove the fuel pump gauge retainer

  14.  
  15. Remove the fuel suction with pump and gauge tube. Do not bend the arm of the sender gauge.
  16.  
  17. Remove the fuel suction tube gasket from the fuel tank.
  18.  
  19. Disconnect the connector of the fuel pump harness.
  20.  
  21. Disconnect the fuel tube.
  22.  
  23. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the fuel filter and fuel pump from the fuel sub-tank.
  24.  
  25. Disengage the 2 claws and remove the fuel suction support from the fuel filter.
  26.  
  27. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the suction filter with fuel pump from the fuel filter.
  28.  
  29. Disconnect the fuel pump harness.
  30.  
  31. Remove the O-ring and fuel pump spacer.

    Click image to see an enlarged view

    Fig. View of the fuel pump module assembly-1 of 2



    Click image to see an enlarged view

    Fig. View of the fuel pump module assembly-2 of 2

  32.  
  33. To install, reverse the removal procedure.
  34.  
  35. Apply gasoline to a new O-ring, and then install the fuel pump spacer and new O-ring onto the fuel pump.
    NOTE
    Do not disassemble the fuel pump and the suction filter because they are non-reusable parts.

  36.  
  37. Check for fuel leakage:
    1. Connect the Techstream to the DLC3.
    2.  
    3. Turn the ignition switch to ON and turn the tester ON.
      NOTE
      Do not start the engine.

    4.  
    5. Select the following menu items: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
    6.  
    7. Check that there is no fuel leakage anywhere on the fuel system after doing maintenance.

      Click image to see an enlarged view

      Fig. fuel tank main tube sub-assembly connection orientation

    8.  

  38.  

 
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