Toyota Highlander Service Manual: Replacement

1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-35 )

2. REMOVE DECK BOARD SUB-ASSY

(a) Disengage the 5 clips and turn up the front side of the deck board.

3. REMOVE REAR SEAT TRACK BRACKET COVER OUTER

4. REMOVE REAR SEAT ASSY RH (See page 72-35 )

5. REMOVE REAR SEAT ASSY LH (See page 72-28 )

6. REMOVE REAR DOOR SCUFF PLATE LH

7. REMOVE REAR FLOOR SERVICE HOLE COVER

(a) Remove the rear floor service hole cover.

(b) Disconnect the fuel pump & sender gauge connector

8. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE

(a) Disconnect the fuel pump tube.

1.  Remove the tube joint clip, and pull out the fuel pump tube.

NOTICE:

• Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.
• Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
• Do not use any tool in this operation.
• Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
• When the pipe and connector are stuck, push and pull the connector to release it. Then pull the connector from the pipe.

(b) Using SST, loosen the fuel pump gage retainer.

SST 09808- 14020 (09808- 01410, 09808- 01420, 09808-01430)

NOTICE: Loosen the retainer by turning it counterclockwise while holding the SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank.

HINT: A rib on the fuel pump gage retainer can be fitted into a tip of the SST.

(c) Remove the fuel pump gage retainer.

(d) Remove the fuel suction tube.

NOTICE: Be careful not to bend the arm of the fuel sender gage.

(e) Remove the gasket from the fuel tank.

9. REMOVE FUEL SENDER GAGE ASSY

(a) Disconnect the fuel sender gage connector.

(b) Unlock the fuel sender gage and slide it to remove.

10. REMOVE FUEL SUCTION PLATE SUB-ASSY

(a) Using a screwdriver with the its wrapped in tape, disconnect the 4 snap-claws from the claw holes and remove the fuel suction plate.

NOTICE: Do not damage the fuel suction plate and fuel suction support No. 1.

11. REMOVE FUEL PUMP ASSY

(a) Disconnect the fuel pump connector.

(b) Using a small screwdriver with the its wrapped in tape, disconnect the 2 snap-claws from the claw holes and pull out the fuel pump.

NOTICE: Do not damage the fuel pump and fuel suction plate.

(c) Remove the O-ring and fuel pump spacer from the fuel pump.

12. REMOVE FUEL PUMP FILTER

(a) Using a small screwdriver, pry out the clip.

(b) Remove the fuel filter from the fuel pump.

13. REMOVE FUEL TUBE JOINT NO.1

(a) Disconnect the connector.

(b) Using a screwdriver with the its wrapped in tape, disconnect the snap-claw from the claw hole and pull out the fuel tube joint.

NOTICE: Do not damage the fuel tube joint and fuel suction plate.

14. REMOVE FUEL PUMP HARNESS

(a) Remove the harness from the fuel tube joint No. 1.

15. REMOVE FUEL PRESSURE REGULATOR ASSY

(a) Remove the clip.

(b) Pull out the pressure regulator from the fuel tube joint No.

1.

(c) Remove the 2 O-rings from the fuel tube joint No. 1.

16. INSTALL FUEL PRESSURE REGULATOR ASSY

(a) Apply a light coat of gasoline or spindle oil to the 2 new O-rings, and install them to the fuel pressure regulator.

(b) Apply a light coat of gasoline or spindle oil to the 2 O-rings again, and install the fuel pressure regulator to the fuel tube joint No. 1.

(c) Install the clip.

17. INSTALL FUEL PUMP HARNESS

18. INSTALL FUEL TUBE JOINT NO.1

(a) Apply a light coat of gasoline or spindle oil to a new Oring, and install it to the fuel tube joint No. 1.

(b) Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel tube joint No. 1 to the fuel suction plate.

(c) Connect the connector.

19. INSTALL FUEL PUMP FILTER

(a) Install the fuel filter with a new clip.

20. INSTALL FUEL PUMP ASSY

(a) Install the fuel pump spacer to the fuel pump.

(b) Apply a light coat of gasoline or spindle oil to a new Oring, and install it to the fuel pump.

(c) Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel pump to the fuel suction plate.

(d) Connect the fuel pump connector.

21. INSTALL FUEL SUCTION PLATE SUB-ASSY

(a) Apply a light coat of gasoline or spindle oil to a new Oring, and install it to the fuel tube joint No. 1.

(b) Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel suction plate to the fuel suction support No. 1.

22. INSTALL FUEL SENDER GAGE ASSY

23. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE

(a) Install a new gasket to the fuel tank.

(b) Attach the fuel suction tube to the fuel tank.

NOTICE: Be careful not to bend the arm of the fuel sender gage.

(c) Align the keyway of the fuel suction tube support with the key of the fuel suction tube.

(d) Apply MP grease to the entire interior surface of the fuel pump gage retainer.

(e) Align the triangle mark on new fuel pump gauge retainer with the "S" mark on the fuel tank while pushing down the fuel suction tube, attach the fuel pump gauge retainer.

(f) Rotate the fuel pump gage retainer by hand, then tighten it one complete turn and half using SST. Triangle mark on the fuel pump gauge retainer must be positioned between "A" and "MAX." indications on the fuel tank.

NOTICE: Do not use other tools in this operation. Damage to the fuel pump gage retainer and the fuel tank may result.

HINT: A rib on the fuel pump gage retainer can be fitted into a tip of the SST.

(g) Connect the fuel pump tube.

1.  Install the fuel pump tube and the tube joint clip.

NOTICE:

• Check that there are no scratches or foreign objects on the connecting part.
• Check that the fuel tube joint is inserted securely.
• Check that the tube joint clip is on the collar of the fuel tube joint.
• After installing the tube joint clip, check that the fuel tube joint has not been pulled off.

24. CHECK FOR FUEL LEAKS (See page 11-38 )

25. INSTALL REAR FLOOR SERVICE HOLE COVER

(a) Install a new butyl tape to the rear floor service hole cover.

(b) Connect the fuel pump & sender gage connector.

(c) Install the rear floor service hole cover.

26. INSTALL REAR DOOR SCUFF PLATE LH

27. INSTALL REAR SEAT ASSY LH (See page 72-28 )

28. INSTALL REAR SEAT ASSY RH (See page 72-35 )

29. INSTALL REAR SEAT TRACK BRACKET COVER OUTER

30. INSTALL DECK BOARD SUB-ASSY