REMOVAL AND REPLACEMENT
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- Janis Gilmore
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1 2005 Scion tc L4-2.4L (2AZ-FE) Vehicle > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Service and Repair REMOVAL AND REPLACEMENT 1/26
2 Fuel Suction W/ Pump And Gauge Tube Assy Part 1 Fuel Suction W/ Pump And Gauge Tube Assy Part 2 2/26
3 3/26
4 FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY Removal & Installation and Disassembly & Reassembly NOTE: When disconnecting the battery terminal, initialize the following system after the terminal is reconnected. - Power window control system - Sliding roof system 1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE RR SEAT CUSHION ASSEMBLY 3. REMOVE REAR FLOOR SERVICE HOLE COVER a. Remove the butyl tape, then remove the rear floor service hole cover. b. Disconnect the fuel pump connector. c. Discharge the fuel system pressure. 1. Start the engine. 2. Turn the ignition switch to OFF after the engine stops. 4/26
5 HINT: DTC P0171 (system too lean) may be present. 3. Crank the engine again and check that the engine does not start. 4. Remove the fuel tank cap, then discharge the pressure in the fuel tank completely. d. Disconnect the wire to wire connector. 4. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY 5/26
6 a. Disconnect the fuel tank main tube. 1. Remove the tube joint clip, then pull the fuel tube joint out of the plug of the fuel suction plate. NOTE: - Remove dirt and foreign objects on the fuel tube joint before performing this work. - Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube joint has the O-ring that seals the plug. - Perform this work by hand. Do not use any tools. - Do not forcibly bend, twist or turn the nylon tube. - Protect the disconnected part by covering it with a vinyl bag and gum tape after disconnecting the fuel tank main tube. 6/26
7 b. Remove the 2 bolts, then remove the fuel tank protector plate. c. Remove the 6 bolts, then remove the fuel tank vent tube set plate. 7/26
8 d. Remove the fuel suction with pump and gauge tube from the fuel tank. NOTE: - Do not damage the fuel pump filter. - Make sure that the fuel sender gauge arm does not bend. 8/26
9 e. Remove the gasket from the fuel suction tube with pump and gauge tube. 5. REMOVE FUEL SENDER GAUGE ASSEMBLY a. Separate the 2 claws fittings, then slide the fuel sender gauge to remove it from the fuel filter. 9/26
10 6. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY a. Disconnect the fuel pump harness connector. b. Using a screwdriver with its tip wrapped in tape, separate the 4 claws fittings. Then remove the fuel suction plate. NOTE: Do not damage the fuel suction plate or fuel tank fuel filter. 7. REMOVE FUEL PUMP HARNESS a. Remove the 2 pump harness terminals. b. Disconnect the pump harness connector, then remove the fuel pump harness. 10/26
11 8. REMOVE FUEL SUCTION SUPPORT NO.2 a. Using a screwdriver with its tip wrapped in tape, separate the 5 claws fittings. Then remove the fuel suction support No. 2. NOTE: Do not damage the fuel suction support No. 2 or fuel tank fuel filter. 9. REMOVE FUEL PUMP CUSHION RUBBER 11/26
12 a. Remove the fuel pump cushion rubber from the fuel pump. 10. REMOVE FUEL PUMP a. Pull the fuel pump out of the fuel filter. 12/26
13 11. REMOVE FUEL PUMP FILTER a. Using a small screwdriver, pry out the clip. b. Remove the fuel pump filter from the fuel pump. 12. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY a. Pull the fuel pressure regulator out of the fuel tank fuel filter. 13/26
14 b. Remove the O-ring from the fuel pressure regulator. 13. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY a. Apply a light coat of gasoline or spindle oil to a new O-ring, then install it onto the fuel pressure regulator. 14/26
15 b. Apply a light coat of gasoline or spindle oil to the O-ring again, then push the fuel pressure regulator into the fuel tank fuel filter. NOTE: Make sure that the O-ring is not cracked or jammed when installing. 15/26
16 14. INSTALL FUEL PUMP FILTER a. Install the fuel pump filter onto the fuel pump. b. Install a new clip. 15. INSTALL FUEL PUMP a. Apply a light coat of gasoline or spindle oil to the O-ring. 16/26
17 b. Push the fuel pump into the fuel tank fuel filter. NOTE: Make sure that the O-ring is not cracked or jammed when installing. 16. INSTALL FUEL PUMP CUSHION RUBBER a. Install the fuel pump cushion rubber onto the fuel pump. 17/26
18 17. INSTALL FUEL SUCTION SUPPORT NO.2 a. Align the claw positions, then install the fuel suction support No. 2 onto the fuel filter. 18. INSTALL FUEL PUMP HARNESS 18/26
19 a. Connect the pump harness connector. b. Install the 2 pump harness terminals. 19. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY a. Apply a light coat of gasoline or spindle oil to the O-ring of the fuel suction plate. 19/26
20 b. Align the claw positions, then install the fuel suction plate into the fuel filter. NOTE: Make sure that the O-ring is not cracked or jammed when installing. c. Connect fuel pump harness connector. 20/26
21 20. INSTALL FUEL SENDER GAUGE ASSEMBLY a. Slide the fuel sender gauge to fit the claws. 21. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY a. Install a new gasket onto the fuel suction with pump and gauge tube. 21/26
22 b. Install the fuel suction with pump and gauge tube into the fuel tank. NOTE: - Do not damage the fuel pump filter. - Make sure that the fuel sender gauge arm does not bend. 22/26
23 c. Install the fuel tank vent tube set plate with the 6 bolts. Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf) d. Install the fuel tank protector plate with the 2 bolts. Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf) 23/26
24 e. Connect the fuel tank main tube. 1. Push the fuel tube joint into the plug of the suction plate, then install the tube joint clip. NOTE: - Check that there are no scratches or foreign objects around the connected part of the fuel tube joint and plug before performing this work. - Check that the fuel tube joint is securely inserted to the end. - Check that the tube joint clip is on the collar of the fuel tube joint. - After installing the tube joint clip, check that the fuel tank main tube cannot be pulled out. 22. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 23. CHECK FOR FUEL LEAKAGE NOTE: Check for fuel leaks with the fuel pump connector connected. 24/26
25 24. INSTALL REAR FLOOR SERVICE HOLE COVER a. Attach new butyl tape to the service hole cover. b. Connect the wire to wire connector. c. Connect the fuel pump connector. d. Install the rear floor service hole cover, making sure it is aligned while aligning it with the 2 convexes of the floor panel. NOTE: Make sure that the rear floor service hole cover does not mount on the convex of the floor panel when installing. 25. INSTALL RR SEAT CUSHION ASSEMBLY 25/26
26 26/26
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