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Disassembly [10/2015 - ]: Procedure

  1. REMOVE FUEL SENDER GAUGE ASSEMBLY 

    See step  2 [10/2015 - 09/2016], or See step  2 [09/2016 - 09/2017], or See step  2 [09/2017 - ]

  2. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY  , or
    1. Disengage the clamp to disconnect the fuel pump harness from the fuel suction plate sub-assembly.
      GTY498819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pump harness connector.
    3. Using needle nose pliers, remove the E-ring from the fuel suction plate shaft.
      GTY517938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 E-ring
    4. Remove the fuel suction plate sub-assembly and spring from the No. 1 fuel sub-tank.
  3. REMOVE FUEL FILTER 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump with filter assembly from the No. 1 fuel sub-tank.
      GTY507349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Do not damage the No. 1 fuel sub-tank or fuel filter.

  4. REMOVE JET PUMP 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the claw and remove the fuel tube.
      GTY512734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    2. Using a screwdriver with its tip wrapped with protective tape, remove the jet pump from the No. 1 fuel sub-tank.
      GTY497482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    3. Remove the O-ring from the jet pump.
      GTY502489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *a Jet Pump
  5. REMOVE NO. 1 FUEL SUCTION SUPPORT 
    GTY508637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 No. 1 Fuel Suction Support
    *a Protective Tape
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws and remove the No. 1 fuel suction support from the fuel filter.
  6. REMOVE FUEL PUMP WITH FILTER ASSEMBLY 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 3 claws, and remove the fuel pump with filter assembly from the fuel filter.
      GTY509327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Filter
      *b Suction Filter
      *c Protective Tape
      NOTE:
      • Do not damage the fuel filter.
      • Do not remove the suction filter.
      • Do not use either the fuel pump with filter assembly or the suction filter if the suction filter is removed from the fuel pump with filter assembly.

        Refer to PRECAUTION [10/2015 - ]

    2. Remove the O-ring from the fuel pump with filter assembly.
      GTY503528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *a 5.0 mm (0.197 in.)
      NOTE:

      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 (1.0 mm (0.0394 in.) diameter) that is formed as shown in the illustration.

  7. REMOVE FUEL MAIN VALVE ASSEMBLY 
    1. Disengage the 2 claws to remove the No. 2 fuel suction support from the fuel filter.
      GTY498742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip wrapped with protective tape, remove the fuel main valve assembly from the fuel filter.
      GTY511914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Slowly pull out the fuel main valve assembly because the O-ring is firmly installed between the fuel main valve assembly and fuel filter.

    3. Remove the 2 O-rings from the fuel main valve assembly.
      GTY470974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
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