Toyota Yaris: Fuel Pump / Removal

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (fuel) / Fuel Pump / 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.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Replacement of fuel pump

Inspection after repair

  • Poor idle, etc.
  • Engine start function, etc.

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 (-) auxiliary battery terminal.
  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

NOTICE:

  • After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 120 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.
  • This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

    Click here

HINT:

When the cable is disconnected/reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

  • Learning completes when vehicle is driven

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Lane tracing assist system

    Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 second or more.

    Pre-collision system

    Stop and start system

    Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)

  • Learning completes when vehicle is operated normally

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Power door lock control system

    • Back door opener

    Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

    Air conditioning system

    After the ignition switch is turned to ON, the servo motor standard position is recognized.

    -

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

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2. DISCHARGE FUEL SYSTEM PRESSURE

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3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

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4. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

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5. REMOVE REAR FLOOR SERVICE HOLE COVER (for LH Side)

(a) Remove the rear floor service hole cover and butyl tape.

(b) Disconnect the 2 connectors from the fuel suction pump and gauge tube assembly.

6. DISCONNECT FUEL TANK EVAP TUBE SUB-ASSEMBLY

(a) Disconnect the fuel tank evap tube sub-assembly from the fuel suction with pump and gauge tube assembly.

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7. DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

(a) Slide the clamp and disconnect the No. 1 fuel evaporation tube sub-assembly from the fuel suction with pump and gauge tube assembly.

8. DISCONNECT CHARCOAL CANISTER OUTLET HOSE

(a) Disconnect the charcoal canister outlet hose from the fuel suction with pump and gauge tube assembly.

9. 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

Tube Joint Clip

*2

Fuel Tank Main Tube Sub-assembly

*a

Nylon Tube

*b

Fuel Tube Joint

*c

Plate Sub-assembly

*d

O-ring

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.

10. REMOVE NO. 1 FUEL TUBE CLAMP

(a) Disengage the claw to remove the No. 1 fuel tube clamp from the fuel pump gauge retainer.

11. REMOVE FUEL PUMP GAUGE RETAINER

(a) 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

SST (Plate)

*b

SST (Bolt)

*c

SST (Claw)

*d

Insertion Point

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

(3) Install SST (handle) and an extension bar to SST (plate).

SST: 09808-14031

09808-01010

SST: 09808-01071

*a

SST (Handle)

*b

SST (Plate)

*c

SST (Bolt)

*d

SST (Claw)

*e

Extension Bar

(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 with pump and gauge tube assembly, remove the fuel pump gauge retainer.

12. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

(a) Disconnect the fuel return vent tube sub-assembly and remove the fuel suction with pump and gauge tube assembly from the fuel tank assembly.

Click here

NOTICE:

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

(b) Remove the gasket from the fuel tank assembly.

    Components

    COMPONENTS ILLUSTRATION *1 CHARCOAL CANISTER OUTLET HOSE *2 FUEL PUMP GAUGE RETAINER *3 FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY *4 FUEL TANK EVAP TUBE SUB-ASSEMBLY *5 FUEL TANK MAIN TUBE SUB-ASSEMBLY *6 NO...

    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...

    Other information:

    Toyota Yaris XP210 (2020-2022) Reapir and Service Manual: Data List / Active Test


    DATA LIST / ACTIVE TEST DATA LIST NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. HINT: Using the GTS to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts...

    Toyota Yaris XP210 (2020-2022) Reapir and Service Manual: Removal


    REMOVAL CAUTION / NOTICE / HINT The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed, installed, or replaced during the engine stop and start ECU removal/installation are shown below...

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