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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 19 (Fuel System (A25A-FXS) - Service Information (2 Of 2)) >> Fuel Pump >> Removal [12/2019 - 10/2022] >> Procedure

Removal [12/2019 - 10/2022]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [12/2019 - 11/2023]

  3. REMOVE BATTERY SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 4

  4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

  5. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (for Captain Seat Type) 

    Refer to REMOVAL [12/2019 - ]

  6. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (for Captain Seat Type) 

    HINT: 

    Use the same procedure as for the LH side.

  7. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (for 60/40 Split Seat Type LH Side) 

    Refer to REMOVAL [12/2019 - ]

  8. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (for 60/40 Split Seat Type RH Side) 

    Refer to REMOVAL [12/2019 - ]

  9. REMOVE REAR CONSOLE BOX ASSEMBLY (for Captain Seat Type) 

    Refer to REMOVAL [12/2019 - ]

  10. REMOVE REAR CONSOLE LOWER BOX 

    Refer to PROCEDURE - Step 11

  11. REMOVE NO. 2 CONSOLE BOX HOLE COVER (w/o Rear Seat Entertainment System) 

    Refer to PROCEDURE - Step 12

  12. SEPARATE FRONT FLOOR CARPET ASSEMBLY 
    1. Remove the 2 clips.
      GTY880832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps.
    3. Turn back the front floor carpet assembly.
  13. REMOVE REAR FLOOR SILENCER 

    Refer to PROCEDURE - Step 6

  14. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the 3 bolts and rear floor service hole cover from the vehicle body.
      GTY880825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK PRESSURE SENSOR (VAPOR PRESSURE SENSOR) 

    Refer to PROCEDURE - Step 2

  16. DISCONNECT FUEL TANK WIRE 
    1. Disconnect the 2 fuel suction tube with pump and gauge assembly connectors.
      GTY880826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the claw to disconnect the fuel tank wire.
  17. DISCONNECT FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank evaporation vent tube sub-assembly from the fuel suction tube with pump and gauge assembly.
      GTY935554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [12/2019 - 11/2023]

  18. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.
      GTY930079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *3 Fuel Tank Main Tube Sub-assembly
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube
      Pull off
      Pull off
      NOTE:
      • Remove any foreign matter on the fuel tube joint before performing this work.
      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
      • Be sure to disconnect the fuel tube joint by hand.
      • Do not bend, twist, pinch or kink the nylon tube.
      • Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
      • If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.
  19. REMOVE FUEL PUMP GAUGE RETAINER 
    1. Disengage the claw to remove the No. 1 fuel tube clamp.
      GTY880827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel pump gauge retainer.
      1. Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.
        • SST: 09808-01071 
        • SST: 09808-14031 
          1. 09808-01030
          2. 09808-01090

        HINT: 

        Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

        GTY876104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Insertion Point
        *b SST (Plate)
        *c SST (Claw)
        *d SST (Bolt)
      2. While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).
      3. Install SST (handle) and an extension bar to SST (plate).
        GTY871774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Handle)
        *b SST (Plate)
        *c SST (Claw)
        *d SST (Bolt)
        *e Extension Bar
        • SST: 09808-14031 
          1. 09808-01010
      4. Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.
        NOTE:
        • Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank sub-assembly.
        • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
        • Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.
        • Do not spin SST too fast or use an impact wrench as this may result in damage to components.
        • If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.
      5. While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.
  20. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    1. Remove the fuel suction tube with pump and gauge assembly from the fuel tank sub-assembly.
      NOTE:

      Be careful not to bend the arm of the fuel sender gauge assembly.

      GTY880816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel suction tube set gasket from the fuel tank sub-assembly.
      GTY880817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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