Electric Fuel Pump-Fuel Injected
REMOVAL & INSTALLATION
The electric fuel pump is contained within the fuel tank. On 1988-92 models, it is necessary to remove the fuel tank from the vehicle in order to reach the pump. On 1993-97 models, the fuel pump can be accessed by removing the rear seat cushion and service hole cover.
1988-92 Models
Fig. 1: Exploded view of the electric fuel pump
NOTE: Before disconnecting fuel system lines, clean the fittings with a spray-type engine cleaner. Follow the instructions on the cleaner. Do not soak fuel system parts in liquid cleaning solvent.
CAUTION
The fuel injection system is under pressure. Release pressure slowly and contain spillage. Observe "no smoking/no open flame'' precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.
- Disconnect the negative battery cable and relieve the fuel pressure. Remove the filler cap.
- Remove the fuel tank from the vehicle.
- Remove the fuel pump bracket attaching screws, then remove the fuel pump/bracket assembly from the tank.
Fig. 2: Remove the bolts retaining the pump bracket to the fuelHow to change a fuel pump on a 1992 Toyota carolla - 88275g78.gif src="/uploads/images/88275g78.gif" alt="88275g78.gif" class="h_mi" />
- Pull the lower side of the fuel pump from the bracket.
- Remove the nuts attaching the wires to the fuel pump.
- Disconnect the hose from the pump.
- Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
Fig. How to change a fuel pump on a 1992 Toyota carolla - 88275g79.gifthe lower portion of the pump from the bracket
Fig. 4: If necessary, remove the clip and pull out the filter to replace it
- While the tank is out and disassembled, inspect it for any signs of rust, leakage or metal damage. If any problem is found, replace the tank.
- Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
- When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
To install:
- Install the pump filter using a new clip. Install the rubber cushion under the filter.
- Connect the outlet hose to the pump, then attach the pump to the bracket.
- Connect the wires to the fuel pump with the nuts.
- Install the fuel pump and bracket assembly onto the tank. Use new gaskets.
- Install the fuel tank.
- Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.
1993-97 Models
CAUTION
The fuel injection system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within aHow to change a fuel pump on a 1992 Toyota carolla - 88275g81.gift all times.
Fig. 5: Exploded view of the fuel pump components
- Disconnect the negative battery cable.
CAUTION
On models with an airbag, wait at least 90 seconds from the time that the ignition switch is turned to the
LOCK position and the battery is disconnected before performing any further work. Refer to Section 7 for all air bag warnings.
How to change a fuel pump on a 1992 Toyota carolla - 88275g82.gif_mi">Relieve the fuel pressure.
- Remove the rear seat cushion.
- Remove the floor service hole cover.
Fig. 6: Remove the 4 service hole cover retaining screws
- Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there.
- Remove the gas cap, thiHow to change a fuel pump on a 1992 Toyota carolla - 88275g83.gifnt any fuel gas spilling out of any high pressure lines.
- Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet pipe from the pump bracket.
Fig. 7: Disconnect the outlet pipe from the pump bracket
- Remove the pump bracket attaching screws.
- Disconnect the return hoses from the pump braHow to change a fuel pump on a 1992 Toyota carolla - 88275g84.gifull out the pump/bracket assembly.
- Remove the nut and spring washer, then disconnect the wires from the pump bracket.
- Remove the sending unit attaching screws, then remove the unit from the bracket.
Fig. 8: Pull the pump bracket with pump attached from the tank
- Pull the lower side of the fuel pump from the bracket.
- Unplug the connector to the fuel pump.
- Disconnect the hose from the pump.
- Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
- Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
- When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
To install:
- Install the pump filter using a new clip. Install the rubber cushion under the filter.
- Connect the outlet hose to the pump, then attach the pump to the bracket and tighten to 22-25 ft. lbs. (29-34 Nm).
- Engage the connector to the fuel pump.
- Install the fuel sending unit to the pump bracket.
- Install the fuel pump and bracket assembly onto the tank. Use new gaskets. Tighten the pump bracket retaining screws to 34 inch lbs. (4 Nm).
- Connect the return hoses to the pump bracket.
- InstHow to change a fuel pump on a 1992 Toyota carolla - prev.gifservice hole cover, then the engage the fuel pump and sending unit connectorHow to change a fuel pump on a 1992 Toyota carolla - next.gifclass="h_mi">Install the rear seat cushion.
- Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.
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