Toyota Avalon (XX50): Fuel Pump

Components

COMPONENTS

ILLUSTRATION

ILLUSTRATION

ILLUSTRATION

Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

NOTICE:

• Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is pressed into the fuel suction plate sub-assembly.
• When replacing the fuel filter, replace it together with the fuel suction plate sub-assembly.

PROCEDURE

1. REMOVE FUEL SENDER GAUGE ASSEMBLY

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2. REMOVE FUEL PUMP

(a) Remove the harness protector from the fuel pump harness.

	Harness Protector
	Fuel Pump Harness Connector

(b) Disconnect the 2 fuel pump harness connectors.

(c) Disengage the clamp to disconnect the fuel pump harness from the fuel suction plate sub-assembly.

NOTICE:

Do not damage the wire harness.

(d) Using a screwdriver with its tip wrapped with protective tape, disengage the claw. NOTICE: Do not damage the fuel sub-tank.

*a Protective Tape *b Fuel Pump Filter Hose

(e) Disengage the clamp and disconnect the fuel pump filter hose from the fuel sub-tank.

NOTICE:

Do not damage the fuel sub-tank.

(f) Disengage the 2 claws and remove the fuel filter from the fuel sub-tank. NOTICE: Do not do anything which may separate the tube from either the fuel suction plate sub-assembly or fuel filter, such as applying excessive force to the tube. Click here

*a Tube

(g) Using a screwdriver with its tip wrapped with protective tape, disengage the 3 claws, and remove the suction filter from the fuel filter. NOTICE: Do not damage the fuel filter or suction filter.

*a Fuel Filter *b Suction Filter *c Protective Tape

(h) Disengage the claw to disconnect the fuel pump harness from the suction filter.

(i) Remove the fuel pump from the fuel filter.

(j) Disconnect the fuel pump harness connector to remove the fuel pump harness from the fuel pump.

(k) Remove the O-ring and fuel pump spacer from the fuel pump. NOTICE: Be careful not to damage the sealing surface. HINT: If the O-ring still remains in the fuel filter, remove it using a wire tip (1 mm (0.0394 in.) diameter) that is formed as shown in the illustration.

*1 O-ring *2 Fuel Pump Spacer *a 5.0 mm (0.197 in.)

Inspection

INSPECTION

PROCEDURE

1. INSPECT FUEL PUMP

(a) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Specified Condition U - V 0.05 to 3.0 Ω V - W 0.05 to 3.0 Ω U - W 0.05 to 3.0 Ω If the result is not as specified, replace the fuel pump.

*a Component without harness connected (Fuel Pump)

Installation

INSTALLATION

PROCEDURE

1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

(a) Install a new fuel suction tube set gasket to the fuel tank assembly.

(b) Set the fuel suction tube with pump and gauge assembly to the fuel tank assembly.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.

(c) Align the protrusions of the fuel suction tube with pump and gauge assembly with the notches in the fuel tank assembly.

*a	Protrusion
	Notch

2. INSTALL FUEL PUMP GAUGE RETAINER

(a) Install the fuel pump gauge retainer.

(1) While pressing down on the fuel suction tube with pump and gauge assembly, temporarily install the fuel pump gauge retainer.

(2) Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer. SST: 09808-14031 09808-01030 09808-01050 SST: 09808-01071 HINT: Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

*a Insertion Point *b SST (Plate) *c SST (Claw) *d SST (Bolt)

(3) While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

(4) Install SST (handle) to SST (plate).

*a	Triangle Mark (Fuel Pump Gauge Retainer)
*b	Triangle Mark (Fuel Tank Assembly)
*c	SST (Handle)
*d	SST (Plate)
*e	SST (Bolt)
	Front Side

SST: 09808-14031

09808-01010

SST: 09808-01071

(5) Using SST, rotate the fuel pump gauge retainer so that the triangle mark on the fuel pump gauge retainer is aligned with the triangle mark on the fuel tank assembly to install the fuel suction tube with pump and gauge assembly to the fuel tank assembly.

NOTICE:

• Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.
• Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
• Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.
• Do not spin SST too fast or use an impact wrench as this may result in damage to components.
• If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.
• Make sure that the fuel suction tube set gasket does not come off.

(b) Engage the claw to install the No. 1 fuel tube clamp.

3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Push the fuel tube joint onto the plug of the fuel suction plate sub-assembly, then install the tube joint clip.

*1	Fuel Suction Plate Sub-assembly	*2	Tube Joint Clip
*3	Fuel Tank Main Tube Sub-assembly	-	-
*a	Fuel Tube Joint	*b	O-ring
*c	Correct	*d	Incorrect
*e	Collar	-	-
	Insert		Insert

NOTICE:

• Check that there are no scratches or foreign matter around the connecting parts 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 sub-assembly is securely connected by pulling on it.

4. INSTALL REAR FLOOR SERVICE HOLE COVER

(a) Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.

(b) Clean the installation surfaces of the rear floor service hole cover and vehicle body.

(c) Connect the 2 fuel pump connectors.

(d) Install the rear floor service hole cover with new butyl tape. NOTICE: Securely install the rear floor service hole cover.

*a Butyl Tape Adhesion Area

5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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6. INSPECT FOR FUEL LEAK

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7. INSTALL REAR SEAT CUSHION LOCK HOOK

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8. INSTALL REAR SEAT CUSHION ASSEMBLY

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9. CONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY

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10. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing the fuel pump.

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Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL FUEL PUMP

HINT:

Perform "Inspection After Repair" after replacing the fuel pump.

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(a) Apply gasoline to a new O-ring. Then install the O-ring and fuel pump spacer to the fuel pump.

*1 O-ring *2 Fuel Pump Spacer

(b) Install the fuel pump to the suction filter.

(c) Engage the 3 claws to install the fuel pump to the fuel filter. NOTICE: Make sure that the O-ring is not cut or pinched during the installation. Securely engage the claws. Do not remove the suction filter from the fuel pump.

(d) Connect the fuel pump harness connector to install the fuel pump harness to the fuel pump.

(e) Engage the claw to connect the fuel pump harness to the fuel pump. NOTICE: Securely engage the claw. Make sure that there is no foreign matter between the fuel pump and the ground terminal of the fuel pump harness. Make sure that the ground terminal of the fuel pump harness is securely connected to the fuel pump body.

(f) Check the connection state of the fuel pump harness.

(1) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

If the result is not as specified, reconnect the fuel pump harness to the fuel pump so that the ground terminal of the fuel pump harness is securely connected to the fuel pump body.

(g) Engage the 2 claws to install the fuel filter to the fuel sub-tank.

NOTICE:

• Do not apply excessive force to the tube or No. 1 fuel suction support.
• Securely engage the claws.

(h) Engage the clamp and claw, and connect the fuel pump filter hose while aligning it with the installation position of the fuel sub-tank. NOTICE: Securely engage the clamp and claw.

(i) Engage the clamp to connect the fuel pump harness to the fuel suction plate sub-assembly.

(j) Connect the 2 fuel pump harness connectors.

(k) Install the harness protector to the fuel pump harness.

2. INSTALL FUEL SENDER GAUGE ASSEMBLY

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Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel pump removal/installation are shown below.

CAUTION:

• Never perform work on fuel system components near any possible ignition sources.
• Vaporized fuel could ignite, resulting in a serious accident.
• Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
• Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

Click here

2. DISCHARGE FUEL SYSTEM PRESSURE

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3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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4. DISCONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY

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5. REMOVE REAR SEAT CUSHION ASSEMBLY

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6. REMOVE REAR SEAT CUSHION LOCK HOOK

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7. REMOVE REAR FLOOR SERVICE HOLE COVER

(a) Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.

*a Protective Tape

(b) Disconnect the 2 fuel pump connectors.

8. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

*1	Fuel Suction Plate Sub-assembly
*2	Tube Joint Clip
*3	Fuel Tank Main Tube Sub-assembly
*a	Fuel Tube Joint
*b	O-ring
*c	Nylon Tube
	Pull off
	Pull off

NOTICE:

• Remove any foreign matter on the fuel tube joint before performing this work.
• Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
• Be sure to disconnect the fuel tube joint by hand.
• Do not bend, twist, pinch or kink the nylon tube.
• Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
• If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.

9. REMOVE FUEL PUMP GAUGE RETAINER

(a) Disengage the claw to remove the No. 1 fuel tube clamp.

(b) Remove the fuel pump gauge retainer.

(1) Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer. SST: 09808-14031 09808-01030 09808-01050 SST: 09808-01071 HINT: Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

*a Insertion Point *b SST (Plate) *c SST (Claw) *d SST (Bolt)

(2) While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

(3) Install SST (handle) to SST (plate). SST: 09808-14031 09808-01010 SST: 09808-01071

*a SST (Handle) *b SST (Plate) *c SST (Claw) *d SST (Bolt)

(4) Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

NOTICE:

• Do not use any tools other than specified in this operation as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.
• Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
• Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.
• Do not spin SST too fast or use an impact wrench as this may result in damage to components.
• If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.

(5) While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.

10. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

(a) Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.

(b) Remove the fuel suction tube set gasket from the fuel tank assembly.