Warning! Gasoline is highly flammable. Therefore, when working with any, take additional precautions. See the warning in paragraph 2.
Application: Once the fuel pump and fuel gauge sender assembly has been removed from the fuel tank, the entire assembly can be replaced, or the assembly can be disassembled and the inlet strainer, fuel pressure regulator, return gauge, fuel pump, fuel filter, or fuel gauge sender replaced. The disassembly procedure shown here is for a typical fuel pump used on 1999-2003 medals. The pump used on 2004 and later models is slightly different.
1. Remove the fuel pump in the block with the fuel level indicator sensor from the fuel tank (see paragraph 5).
2. Drain the remaining gasoline from the fuel pump in the sensor unit, and then install the unit on a clean workbench. Make sure the work area is well ventilated, because gasoline will evaporate from the fuel pump for some time.
3. Carefully pry the end cap off the lower end of the fuel pump in the sensor unit (Fig. 6.3).
Fig. 6.3. To remove the lower end cap, carefully use a pair of screwdrivers to release each of the locking tabs, then remove the cap
4. Remove the rubber support from the lower end of the fuel pump (Fig. 6.4).
Fig. 6.4 Remove the small rubber support shown from the lower end of the fuel pump and inspect it. If damaged, replace it
5. Remove the fuel pump inlet mesh filter (Fig. 6.5) from the lower end of the fuel pump.
Fig. 6.5. The inlet strainer is secured to the lower end of the fuel pump with an E-clip. To release the strainer from the pump, insert a screwdriver between the strainer support flange and the pump, and gently pry the strainer and E-clip out to release them (do not attempt to pry the clip directly - it is too difficult to insert a screwdriver under it)
6. Remove the fuel pressure regulator (Fig. 6.6).
Fig. 6.6. Disconnect the fuel pressure regulator from the calibrated return hose (A) and from the fuel filter (B)
7. Remove the return calibrated pipe assembly (Fig. 6.7).
Fig. 6.7 To disconnect the calibrated return pipe assembly, simply pull it out of the clamp (A)
8. Remove the fuel pump from the fuel filter assembly (fig. 6.8, a, b).
Fig. 6.8, a. To disconnect the fuel pump electrical connector, press in on the locking tab and pull out the plug
Fig. 6.8, b. To remove the fuel pump from the fuel filter housing, pull it away from the bottom
9. Separate the fuel filter housing from the upper section of the fuel pump assembly (Fig. 6.9). If you are replacing the fuel filter, you must replace this housing. The fuel filter is not supplied separately from the housing.
(The original text is posted on www.ToyotaMan.ru)
Fig. 6.9 To separate the fuel filter housing from the upper section of the pump assembly, carefully release the four retaining tabs from the filter housing and pull both elements in opposite directions
10. Disconnect the fuel level indicator sensor from the upper section of the fuel pump assembly (Fig. 6.10).
Fig. 6.10. To remove the fuel level sensor from the upper section of the fuel pump assembly, release both retaining elements from the tabs on the upper section of the pump, then slide the sensor straight down. When installing the sensor, slide it into place until the two retaining elements snap into the tabs
11. Assembly is performed in the reverse order of disassembly.
12. Install the fuel pump in the block with the fuel level indicator sensor in the fuel tank (see paragraph 5).