Removal

2GR-FSE FUEL: FUEL PUMP: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Service Precautions.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3. REMOVE REAR SEAT CUSHION ASSEMBLY Removal

4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER

(a) Remove the No. 2 rear floor service hole cover and disconnect the fuel suction tube connector.

5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

(a) Disconnect the connector from the fuel suction with pump and gauge assembly.

(b) Disconnect fuel pump tube.

NOTICE:
Before beginning this procedure, check for foreign matter on the joint clips. Clean if necessary.

(1) Remove the 2 tube joint clips, fuel tank main tube and fuel tank return vent tube.

NOTICE:
* Keep the O-ring free of 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 it.
* Be careful not to damage any clips. If a clip is damaged, replace it.
(c) Remove the 8 bolts and the fuel tank vent tube set plate.

HINT
While holding the fuel suction tube by hand, remove the fuel tank vent tube set plate.

(d) Disconnect the fuel tube.

(e) Remove the fuel suction tube from the fuel tank.

HINT
* Make sure that the fuel sender gauge arm does not bend.
* Do not damage the No. 2 fuel hose.
6. REMOVE FUEL SENDER GAUGE ASSEMBLY

(a) Disconnect the fuel sender gauge connector.

(b) Press down on the sender gauge claw labeled A. Then slide the sender gauge upward.

7. REMOVE NO. 1 FUEL SUB-TANK

(a) Using needle nozzle pliers, remove the E-ring.

(b) Using a screwdriver with the tip taped, disengage the claw and remove the jet pump nozzle.

(d) Using a clip remover with the tip taped, remove the jet pump and No. 1 fuel sub-tank.

NOTICE:
The O-ring is installed firmly between the jet pump and No. 1 fuel sub-tank. Therefore, the jet pump and No. 1 fuel sub-tank should be removed carefully using a clip remover.

8. REMOVE FUEL PUMP

(a) Disconnect the 2 connectors and terminal and remove the fuel pump wire.

(b) Using a screwdriver with the tip taped, detach the 2 claws from the claw holes and remove the fuel pump.

NOTICE:
If the fuel pump seal still remains in the fuel filter, remove it using a wire tip (dia1 mm) that is formed as shown in the illustration. Be careful not to damage the sealing surface.

9. REMOVE FLANGE ASSEMBLY

(a) Using a screwdriver with the tip taped, disengage the 2 claws and remove the flange assembly.

10. REMOVE FUEL RELIEF VALVE ASSEMBLY

(a) Using a screwdriver with the tip taped, disengage the claw and remove the fuel relief valve assembly.

11. REMOVE JET PUMP

(a) Using a screwdriver with the tip taped, disengage the 2 claws and remove the jet pump.

12. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY

(a) Remove the clip and fuel pressure regulator from the relief valve.

(b) Remove the 2 O-rings from the fuel pressure regulator.