Toyota 83320-60440 Gage Assy, Fuel Sender

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To remove the fuel pump/fuel gauge sending unit, start by relieving the system fuel pressure. Then, proceed to remove the fuel tank and disconnect the quick-connect fittings for the fuel supply and return lines. Before unscrewing the retainer ring that secures the fuel pump/fuel gauge sending the unit to the fuel tank, take note of the lock tabs and lugs. As you loosen the retainer ring, push out each lock tab as it approaches each lug to clear them and prevent damage. Use a suitable tool to unscrew the retainer ring and carefully withdraw the fuel pump/fuel gauge sending unit assembly from the fuel tank, ensuring not to damage the fuel pump filter or bend the sending unit float arm. Inspect and replace the fuel pump/fuel gauge sending unit O-ring if necessary. If you want to replace the fuel pump or fuel level sending unit, this is the appropriate time. While the pump is removed, inspect the pump inlet strainer for any clogs or damage, cleaning it in a clean solvent if necessary or replacing it if still clogged. When installing the fuel pump/fuel gauge sending unit, align the locator lug on the pump flange with the notch in the pump mounting ring. Tighten the retainer ring by screwing it down two turns, then position the alignment mark on the ring between the two arrows on the fuel tank. Finally, installation is the reverse of removal.

To remove the fuel pump/fuel gauge sending unit from the fuel tank, start by removing the fuel tank itself. Once the tank is removed, proceed to detach the vapor pressure sensor by removing its retaining clip. Disconnect the fuel gauge sending unit electrical connector and release the lock tab to slide off the sending unit from the pump sub-tank. Disengage the four snap claws securing the fuel filter to the sub-tank using four screwdrivers, and remove the fuel filter assembly. Disconnect the electrical connector from the fuel pump and disengage the two snap claws securing the fuel pump to the fuel filter assembly. Remove the fuel pump from the fuel filter assembly and inspect the fuel pump outlet O-ring, removing it along with the fuel pump spacer. Pry off the retaining clip and remove the pump inlet filter. The reassembly process is the reverse of disassembly, ensuring to use a new retaining clip on the inlet filter. For the second set of instructions, to remove the fuel pump/fuel gauge sending unit from the fuel tank, begin by removing the fuel tank itself. Disconnect the fuel gauge sending electrical connector and unlock the fuel gauge sending unit to remove it. Disconnect the fuel pump electrical connector from the upper suction plate. Disengage and detach the suction filter hose from the fuel sub-tank and separate the two tubes from the clamps on the lower suction plate. Using a screwdriver, disengage the three snap-claws securing the lower suction plate to the fuel sub-tank and carefully separate the upper and lower suction plates, along with the fuel filter. Disengage the two snap claws to separate the fuel suction support and remove the fuel pump and pump inlet filter from the fuel filter. Disconnect the electrical connector from the fuel pump and remove the O-ring, inspecting its condition and replacing it if necessary. Using a screwdriver, remove the two E-rings from the lower suction plate, followed by removing the lower suction plate and two springs from the upper suction plate. Once separated, the upper and lower suction plates can be replaced, along with the fuel filter. The installation process is the reverse of removal, ensuring to use a new retaining clip on the inlet filter.