Toyota 83320-0C040 Gage Assembly, Fuel Send

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To remove the fuel pump or fuel gauge sending unit on certain engines, the entire assembly must be replaced. The process begins by relieving the system fuel pressure and removing the fuel tank. The electrical connector is then disconnected from the fuel pump/Fuel Level Sensor, and the tube joint U-clips are removed to disconnect the fuel supply and return line fittings. The threaded fuel pump retaining ring is loosened using a pump retainer removal tool or large pair of channel lock pliers, while pushing the locking tabs inwards to prevent them from locking against the tabs on the unit face. The fuel pump/Fuel Level Sensor is carefully withdrawn from the fuel tank, and the O-ring seal is removed. If the fuel pump or Fuel Level Sensor needs to be replaced, the two components must be separated. For the Fuel Level Sensor, the fuel gauge sending unit electrical connector is disconnected, and the lock tab is released to slide off the sender. For the fuel pump, the Fuel Level Sensor is removed, and the fuel pump electrical connector is disconnected. The suction filter hose is detached from the fuel sub-tank, and the plastic tubes are disengaged from the tube guides on top of the fuel suction plate. The three snap-claws securing the fuel suction plate to the fuel sub-tank are disengaged, and the fuel suction plate and fuel suction filter are separated. The five snap-claws are disengaged from the fuel suction filter, and the suction filter is removed from the fuel pump. The fuel pump harness electrical connector is disconnected, and the O-ring is removed from the fuel filter or fuel pump. If necessary, the fuel pressure regulator and housing can be replaced as a unit by disengaging the snap-claws and replacing the unit. To install the components, the regulator is pushed into the housing with new O-rings, the spacer and new O-ring are installed on the pump, and the electrical connector is connected to the pump. The fuel pump is then slid into the assembly, aligning it with the outlet, and the five snap-claws of the fuel suction filter are engaged with the assembly. The remaining installation steps are the reverse of removal, ensuring that the locking tab is seated and the electrical connector is installed on the fuel level sensor.

The threaded fuel pump retaining ring can be loosened using a pump retainer removal tool or large pair of channel lock pliers, while pushing the locking tabs inwards to prevent them from locking against the tabs on the unit face.