Genuine Toyota Highlander Fuel Level Sensor

Toyota Highlander Fuel Level Sensor Parts Questions & Answers

• Gage Assy, Fuel Sender
  83320-48040
  Q: How to disassemble a fuel pump/fuel level sending unit?

  A: To replace or repair the components of a fuel pump/Fuel Level Sensor, start by removing the Fuel Level Sensor from the fuel tank and draining residual gasoline. For models up to 2007 (excluding 2007 RX 350), carefully pry off the end cap and remove the rubber insulator, fuel pump inlet strainer, fuel pressure regulator, fuel return jet tube assembly, and fuel pump from the fuel filter assembly. Then, separate the fuel filter housing and detach the Fuel Level Sensor from the upper part of the pump assembly. For installation, reverse the disassembly process. For 2007 RX 350 and models from 2008 onwards, the components are modular. Disconnect the fuel sender electrical connector to remove the Fuel Level Sensor, and disconnect the fuel pump electrical connector to remove the fuel pump. Additionally, remove and inspect the strainer for contamination. For 2GR-FKS models, remove the fuel pump module and the hairpin clip from the module body, and then pull the main valve from the module body. Replace the O-ring on the main valve, lubricate it with clean fuel, and press it into its original bore. Reinstall the hairpin clip and complete the remaining assembly in reverse order.
• Gage Assy, Fuel Sender
  83320-0E010
  Q: How to remove and install a fuel pump and Fuel Level Sensor on Toyota Highlander?

  A: This procedure depicts a typical pump used on 2003 and earlier models. The pump used on later models is slightly different. Remove the rear seat. Note that on 2007 and later models, once the rear seats are removed from the vehicle it will be necessary to disassemble the rear section components and lift the carpet to gain access to the fuel pump module cover. Remove the fuel pump/Fuel Level Sensor floor service hole cover by carefully prying it out with a screwdriver. Relieve the fuel system pressure and remove the fuel tank cap. Disconnect the fuel pump electrical connector by depressing the release tab and pulling up. Disconnect the cable from the negative battery terminal. Disconnect the fuel supply line from the top of the fuel pump unit by removing the clip and pulling the fitting straight up. Before reconnecting the fitting, inspect the O-ring inside the fitting and replace if damaged. Remove the retaining bolts from the fuel pump/Fuel Level Sensor mounting flange on 2006 and earlier models, or remove the retaining ring on 2007 and later models using a special tool. Carefully lift the fuel pump/Fuel Level Sensor assembly from the fuel tank, angling it to protect the fuel inlet strainer and the Fuel Level Sensor float. Inspect the fuel pump inlet strainer for contamination and clean if necessary. When installing the retaining ring on 2007 and later models, align the triangle mark on the retaining ring with the "S" mark on the fuel tank and tighten 1-1/2 turns. The triangle mark must be positioned between the MIN and MAX marks on the fuel tank. The remainder of installation is the reverse of removal.