Toyota 23220-16190 Fuel Pump Assembly

To check fuel pump operation, turn the ignition switch on but do not start the engine and connect terminals +B and Fp of the fuel pump check connecter using a jumper. Check the sound of fuel returning from the control, pressure of fuel through the regulator, check the pressure in the hose from the filter. Disconnect the jumper wire and unscrew the cap of the service electrical connector, finally switch off the ignition switch. Without pressure, they should check the EFI 15-amp fuse, the ignition 7.5-amp fuse, the EFI main relay, the fuel pump and, finally, the wiring and the electrical connectors. To perform the fuel pressure check, a fuel pressure gauge with an 8m banjo fitting will be needed. Others involve using a nipple by connecting this to an 8 mm banjo fitting that fits the fuel pressure gauge hose or a makeshift adapter created by making a nut from the 8 mm bolt. You must pull the fuel tank cap, check the battery voltage for being 12 or more, take out negative battery terminal, and disconnect the electrical connection of the cold start injector. Position a can underneath the cold start injector pipe banjo bolt then remove the banjo bolt and connect the fuel pressure gauge. Any dripping gasoline should be wiped off, the negative terminal of the battery reconnected, the transaxle shifted into Neutral or Park and the parking brake engaged. Connect +B and Fp of the check electrical connector, switch on the ignition and check the fuel pressure at idle on the gauge against the recommended pressure. If the system shows high pressure, then search for a restricted fuel return line; if the pressure is low, then pinch the fuel return line and observe if there is a rise in pressure. Once the jumper wire is disconnected, turn the engine on, then unscrew the vacuum sensing hose from the fuel pressure regulator, check the fuel pressure when the engine is idling, then reconnect the hose back. Ensure the fuel pressure is at the onset of 21 psi or above steady for five minutes after shutting down the engine. Remove a negative battery terminal, unscrew the fuel rail pressure test connector slowly, reattach the cold start pipe banjo connector along with new crush washers, rejoin the electrical connection to the cold start injector, and for any spilt gasoline, wipe clean. Last but not the least attach the negative battery cable and then take the car for drive to see that whether there is any leakage or not.

1988 through 1990 models do not have an access hole for fuel pump removal, so the fuel tank needs to be removed to gain access to the fuel pump. On 1991 and later models, the middle seat needs to be removed to uncover the fuel pump access cover for fuel pump testing and replacement procedures. To remove the fuel pump, first relieve the fuel system pressure and disconnect the cable from the negative terminal of the battery. On 1988 through 1990 models, remove the fuel tank from the vehicle. On 1991 and later models, remove the middle seat and lift off the fuel pump/sending unit access cover. Disconnect the electrical connector and fuel lines, and remove the fuel pump/sending unit retaining bolts. Carefully withdraw the fuel pump/fuel level sending unit assembly from the fuel tank, making sure not to damage the inlet screen or float arm. Pry the lower end of the fuel pump loose from the bracket and remove the rubber cushion. Remove the clip securing the inlet screen to the pump and inspect the screen for contamination. If dirty, replace it. If only replacing the fuel pump inlet screen, install the new screen, clip, and rubber cushion, and push the lower end of the pump back into the bracket. If replacing the fuel pump, remove the hose clamp at the upper end of the pump and disconnect the pump from the hose. Disconnect the wires from the pump terminals and remove the pump. Installation is the reverse of removal, making sure to use new sealing washers on either side of the banjo fitting if applicable, and tighten the fitting bolt.

Relieve the fuel pressure, then disconnect the cable from the negative terminal of the battery. Remove the fuel tank and place it on a workbench. Next, remove the clamp bolt securing the fuel pump feed and return lines to the fuel tank, followed by the five fuel pump retaining screws. Carefully withdraw the fuel pump/bracket assembly from the fuel tank and pull the lower end of the fuel pump loose from the bracket, removing the rubber cushion that insulates the bottom of the pump. Take off the rubber cushion from the lower end of the fuel pump and remove the clip securing the filter to the pump, prying off the clip holding the strainer to the fuel pump and pulling the strainer loose; replace the clip if it is a loose fit. Pull out the filter and inspect it for contamination, replacing it if it is dirty. If only the fuel pump filter is being replaced, install the new filter, the clip, and the rubber cushion, push the lower end of the pump back into the bracket, install the pump/bracket assembly in the fuel tank, and reinstall the fuel tank. If replacing the fuel pump, loosen the hose clamp at the upper end of the pump and disconnect the pump from the hose, pulling the fuel pump loose from the hose far enough to access the electrical lead near the bracket. Disconnect the electrical wires from the pump terminals and remove the pump. Installation is the reverse of removal.Additionally, if the Fuel Level Sensor needs to be replaced, locate it on the fuel tank, disconnect the wiring harness, and remove any retaining screws or clips. Carefully pull the Fuel Level Sensor out of the tank, taking care not to damage the sealing surface. Install the new Fuel Level Sensor by reversing the removal steps, ensuring a proper seal and secure connections.

Disconnect the cable from the negative terminal of the battery. Caution: If the stereo in your vehicle is equipped with an anti-theft system, refer to the information on page 0-15 at the front of this manual before detaching the cable.

The fuel pump is located on the side of the engine block.

Turn ON the ignition switch (but do not start the engine).

Check the fuel pump and lines for any obvious damage or fuel leakage. Also check all hoses from the tank to the pump, particularly the suction hoses at the fuel tank and pump.