Toyota 77020-04061 Fuel Suction Tube Assembly W/Pump & Gage

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If you suspect insufficient fuel delivery, first check the battery to ensure it is fully charged. Inspect all fuel lines for leaks. Verify that the fuel pump is running by listening for a brief whirring noise when the ignition switch is turned on. If the fuel pump does not make a sound, check the fuel pump electrical circuit and make sure the connector is securely connected. To check the fuel pressure, relieve the fuel system pressure and connect a fuel pressure gauge between the fuel rail and the fuel feed line. Start the engine and compare the fuel pressure with the specified value. If the pressure is too low, pinch the fuel return line to see if the pressure increases. If it does not, the fuel pressure regulator may need to be replaced. If the pressure is too high, check for vacuum at the fuel pressure regulator and apply vacuum with a hand-held vacuum pump. If the pressure does not decrease, the pressure regulator is faulty. Check the fuel return line for obstructions and replace the fuel pressure regulator if necessary. After completing the fuel pressure check, reconnect the fuel supply hose and check for leaks.

Remove the fuel tank and remove the fuel pump/fuel gauge sending unit from the tank.Disconnect the fuel gauge sending unit electrical connector.To detach the fuel gauge sending unit from the pump sub-tank, release the lock tab and slide the sending unit down.To install the fuel gauge sending unit on the sub-tank, align the T-shaped recess in the underside of the fuel gauge sending unit with the T-shape lug on the sub-tank, then lit the gauge on the sub-tank and push down until the lock tab snaps into place.Install the fuel pump/fuel gauge sending unit into the tank and install the fuel tank.Disconnect the upper end of the fuel pump harness from the underside of the fuel pump module mounting flange.Using three screwdrivers, disengage the three claw fittings that secure the sub-tank to the lower end of the fuel pump module mounting flange assembly, then remove the fuel filter assembly from the fuel sub-tank.Using screwdrivers, disengage the two claw fittings that secure the fuel filter housing/fuel pump/fuel pressure regulator assembly to the wall of the sub-tank, pull the filler/pump/pressure regulator out of the sub-tank and disconnect the electrical connector from the fuel pump.Using a screwdriver, disengage the three claw fittings that secure the inlet strainer to the fuel filter housing and the two claw fittings that secure the strainer to the fuel pressure regulator, then pull the inlet strainer off the lower end of the fuel pump.Pull the fuel pump out of the fuel filter housing, pull the harness through the upper end of the filter housing, then disconnect the harness connector from the upper end of the fuel pump. 1To remove the fuel pressure regulator from the fuel filter housing, simply pull it out. Inspect the condition of the two pressure regulator 0-rings.Reassembly is the reverse of disassembly.

Relieve the system fuel pressure. Remove the fuel tank. Disconnect the fuel supply and return line quick-connect fittings from the fuel pump/fuel gauge sending unit module by sliding back the yellow locking retainers and pulling up on the fittings. Note how the fuel and supply lines are routed across the top of the fuel tank, then detach them from the tank. Using a suitable tool, unscrew the retainer ring. As you turn the ring, bend each locking tab to clear the locking lugs. Carefully withdraw the fuel pump/fuel gauge sending unit assembly from the fuel tank. Make sure you don't damage the fuel pump filter or bend the sending unit float arm. Remove and inspect the fuel pump/fuel gauge sending unit 0-ring. If the 0-ring is cracked, torn or deteriorated, replace it. If you want to replace either the fuel pump or the fuel gauge sending unit, proceed accordingly. If you have been experiencing fuel delivery problems, disassemble the pump assembly while the pump is removed and inspect the pump inlet strainer. Make sure that it's not clogged or damaged. If the strainer is dirty, try washing it in clean solvent. If it's still clogged, replace the pump assembly. When installing the fuel pump/fuel gauge sending unit, make sure that the locator lug on the edge of the pump mounting flange is aligned with the notch in the pump mounting ring. When tightening the retainer ring, screw it down a couple of turns, then turn it so that the alignment mark on the ring is positioned between the two arrows on the fuel tank. Installation is otherwise the reverse of removal.

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