Toyota 23220-16190 Fuel Pump Assembly

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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.

Remove the fuel tank cap.

Listen for fuel return noises from the fuel pressure regulator and verify that there is pressure in the hose from the fuel filter.

Use a fuel pressure gauge capable of measuring a minimum of 50psi.

Be sure the fuel hoses and lines are in good shape and not plugged, then replace the pump.

Before installation, coat both sides of the gasket surface with RTV sealant, position the gasket and fuel pump against the block, and install the bolts, tightening them securely.