Toyota 23221-03040 Fuel Pump Assembly

To remove the fuel pump/Fuel Level Sensor from a vehicle, first, relieve the fuel system pressure and disconnect the cable from the negative terminal of the battery. Then, remove the rear seat from inside the passenger compartment and the fuel pump/sending unit floor service hole cover. Disconnect the electrical connector and fuel line, and remove the retaining bolts before carefully withdrawing the assembly from the fuel tank. Disconnect the electrical connector from the fuel pump and remove the pump from the assembly, either by sliding the hose clamp up the hose or by removing the fuel-sending unit and fuel filler and prying up the housing snap-retainers in sequence. Finally, remove the clip securing the inlet strainer to the pump and inspect it for contamination before replacing it if necessary. To install the fuel pump/sending unit assembly, reassemble it in the reverse order of disassembly and connect the fuel line and electrical connector before completing the remainder of the installation in reverse.

Before working on Solara models, make sure your fuel tank has enough fuel and inspect the fuel pump using the ignition key. Turn the key to ON to hear the fuel pump activate with a quick whirring noise for a few seconds. When no sound comes from turning the ignition on, look at the fuse situation in the engine compartment: examine IGN, EFI, C/OPN, and EFI relays and fuse. Look for voltage at the fuel pump connector whenever the ignition is running. If you find power there for two seconds, the fuel pump is bad; otherwise, the PCM may need repair. To measure fuel pump pressure, you must release any fuel system pressure, disconnect the fuel line from the fuel rail, then use a special tool to separate the fuel line's quick connecting fittings. Connect fuel pressure lines along with clamps from the fuel rail to the feed line, turn the car's ignition, and write down the pressure value shown on the gauge. The fuel pump runs for two seconds when you turn on the ignition. Afterward, the pressure stays constant while the pump is off. Kick the engine on and keep it running; the fuel pressure should hold at its correct level. Watch the gauge reading on the fuel pressure regulator. Where it falls outside of allowed limits, the fuel pressure regulator must be replaced if your reading shows excessive pressure, while you must lookout for clogged filters or cracked fuel lines and test fuel injectors if reading is low. Keep replacing both parts if you're still experiencing low pressure so your car won't have ongoing issues. After checking fuel pressure, drop the gauge and remove pressure from the fuel system.

To remove the fuel pump, first relieve the fuel system pressure and remove the fuel tank cap. Disconnect the cable from the negative terminal of the battery and drain as much fuel from the tank as possible into a proper gasoline container. Lower the fuel tank with a transmission-type jack until the fuel pump connectors are accessible, noting the differences between the fuel pump assembly for the 1998 to 2000 models and later models. Disconnect the electrical connector and the fuel line, and if there are quick-connect fittings, address those accordingly. Remove the retaining screws for the fuel pump/sending unit, set the cover aside, and carefully withdraw the assembly from the tank. Disconnect the electrical connector from the fuel pump and remove the pump from the assembly, following specific steps for different model years regarding the fuel sender, fuel filter, and pressure regulator. Inspect the fuel strainer for contamination and replace it if necessary. For installation, reassemble the fuel pump/sending unit in reverse order, install the assembly in the fuel tank, and connect the fuel line and electrical connector, ensuring any quick-connect fittings are properly addressed. The remainder of the installation follows the reverse of the removal process.

Check the circuit from the fuse/relay box to the battery or ignition switch.

You should first ensure that there is enough fuel in the tank and that the fuel pump runs by listening for a whirring noise when the ignition is turned on.