This procedure removes and replaces the fuel pump module assembly accessed through the rear seat area. This is a safety-critical job involving pressurized flammable fuel.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Toyota 77020-02390 or equivalent
• Fuel pump seal/gasket × 1 — Toyota 77168-02010
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground outdoors or in a well-ventilated garage. Turn off engine and remove key.
2. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge.
3. Ensure fuel tank is at 1/4 tank or less. If necessary, siphon fuel into approved containers before beginning.
4. Allow engine and exhaust system to cool completely (minimum 2 hours after last operation).
5. Remove all ignition sources from work area. No smoking, welding, or open flames within 50 feet.
6. Place Class B fire extinguisher within immediate reach.
7. Put on nitrile gloves and safety glasses.

Procedure

1. 1

   Relieve fuel system pressure
   With engine off and key removed, locate the fuel pump relay or fuse in the engine bay fuse box (consult owner's manual for exact location, typically labeled EFI or FUEL PUMP). Remove the fuel pump relay/fuse. Attempt to start the engine; it should crank but not start or run briefly then stall. Crank for 5 seconds to ensure pressure is relieved. The fuel system is now depressurized.
   ⚠️This step is CRITICAL. Skipping this step will result in high-pressure fuel spray when lines are disconnected.
2. 2

   Remove rear seat cushion
   Enter rear passenger area. Locate the two seat cushion retaining clips at the front edge of the rear seat bottom cushion (one on each side). Push down and pull forward firmly on the front edge of the seat cushion to disengage clips. Lift the entire rear seat bottom cushion up and out of the vehicle. Set aside in a clean area.
3. 3

   Remove fuel pump access cover
   With the rear seat removed, locate the rectangular fuel pump access cover in the floor pan (driver's side). Peel back the carpet or sound deadening material. Remove the four Phillips screws securing the metal access cover. Carefully lift the access cover to reveal the fuel pump module. You should see the fuel pump assembly with electrical connector and fuel lines attached.
   Torque spec

   Access Cover Screws4 Nm (3 lb-ft)
4. 4

   Disconnect electrical connector
   Locate the fuel pump electrical connector on top of the fuel pump module. Press the locking tab and pull the connector straight up to disconnect. Inspect connector terminals for corrosion. Do not allow connector to fall into tank area.
5. 5

   Disconnect fuel lines
   Identify the fuel feed line and fuel return line (if equipped) connected to the top of the pump module. Place shop towels around the connection area to catch residual fuel. Using the appropriate fuel line disconnect tool, depress the retaining tabs and pull the lines straight off the pump module fittings. Expect 30-60ml of fuel to drain from lines. Plug or cap the disconnected lines to prevent contamination.
   ⚠Even with pressure relieved, residual fuel will drain from lines. Have absorbent materials ready and ensure adequate ventilation.
6. 6

   Remove fuel pump lock ring
   Using the fuel pump lock ring tool (Toyota SST 09808-14020 or equivalent), position the tool onto the lock ring tabs. Strike the tool handle sharply with your hand or soft mallet in a counterclockwise direction to break the lock ring free. Once loosened, rotate the lock ring counterclockwise by hand until it can be lifted off. Remove and inspect the lock ring for damage or corrosion.
   ⚠️Do NOT use metal hammers or tools that could create sparks near the open fuel tank.
   ⚠The lock ring tool is ESSENTIAL. Do not attempt to remove the lock ring with screwdrivers or punches as this will damage the ring and tank.
   Torque spec

   Fuel Pump Lock Ring64 Nm (48 lb-ft)
7. 7

   Remove fuel pump module
   Carefully lift the fuel pump module assembly straight up out of the fuel tank opening. Tilt the module slightly to maneuver the float arm and fuel level sender past the opening. Be aware that fuel will drain from the module reservoir (approximately 100-200ml). Keep the module over the tank opening or shop towels. Once clear, set the module in a drain pan. Remove and discard the old fuel pump seal/gasket from the tank opening.
   ⚠The fuel level sender float arm and strainer assembly are fragile. Handle carefully to avoid bending or breaking components.
8. 8

   Inspect fuel tank opening
   With the pump removed, inspect the fuel tank opening and sealing surface. Look for debris, rust, or damage. Wipe the sealing surface clean with a lint-free cloth. Do not allow any debris to fall into the fuel tank. Check inside the tank (using a flashlight) for contamination or debris. If significant debris is present, the tank should be removed and cleaned professionally.
9. 9

   Install new fuel pump module
   Install the new fuel pump seal/gasket onto the tank opening, ensuring it is properly seated in the groove. Compare the new fuel pump module to the old unit to verify correct replacement. Carefully lower the new module into the tank opening, tilting as necessary to clear the float arm and strainer. Ensure the module is fully seated and the alignment marks (if present) match the tank orientation. The module should sit flush against the seal.
   ⚠Verify the fuel pump seal is correctly positioned before installing the module. An improperly seated seal will cause fuel leaks and potential fire hazard.
10. 10

    Install and torque lock ring
    Place the lock ring over the fuel pump module and align the tabs. Using the lock ring tool, rotate the ring clockwise until hand-tight. Using a torque wrench with the lock ring tool, torque the lock ring to specification by striking or pulling the tool handle in a clockwise direction. Verify the lock ring is fully seated and secure.
    ⚠️CRITICAL: Proper torque on the lock ring is essential to seal the fuel tank and prevent leaks. Under-torquing will cause fuel leaks. Over-torquing may damage the tank threads.
    Torque spec

    Fuel Pump Lock Ring64 Nm (48 lb-ft)
11. 11

    Reconnect fuel lines
    Install new O-rings onto the fuel pump module fittings (lubricate lightly with clean gasoline if needed). Push the fuel feed line and return line (if equipped) onto the pump module fittings until you hear/feel a distinct click. Pull back on each line to verify it is locked in place. The lines should not pull off with moderate force.
    ⚠️CRITICAL: Fuel line connections must be fully engaged and locked. Improperly connected lines will leak under pressure and cause fire risk.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
12. 12

    Reconnect electrical connector
    Push the electrical connector firmly onto the fuel pump module until the locking tab clicks into place. Tug gently on the connector to verify it is locked. Ensure no wires are pinched or stressed.
13. 13

    Reinstall access cover and rear seat
    Position the metal access cover over the fuel pump opening and install the four screws. Torque screws to specification in a cross pattern. Reposition carpet or sound deadening material. Reinstall the rear seat bottom cushion by inserting the rear tabs first, then pressing down firmly on the front edge until both clips engage with a solid click.
    Torque spec

    Access Cover Screws4 Nm (3 lb-ft)
14. 14

    Restore fuel system and prime
    Reconnect the negative battery terminal. Reinstall the fuel pump relay/fuse removed in Step 1. Without starting the engine, turn the ignition key to ON position (do not crank). Listen for the fuel pump to run for 2-3 seconds to prime the system. Turn key OFF and wait 5 seconds. Repeat this key cycle 3-4 times to fully prime the fuel system and check for leaks.
15. 15

    Perform leak check and test drive
    With the ignition ON but engine not running, carefully inspect all fuel line connections at the pump module for leaks. Look and smell for any signs of fuel. If no leaks are detected, start the engine. Allow it to idle for 2-3 minutes while monitoring for leaks and unusual noises. Check that fuel pressure is stable (engine should idle normally without stumbling). If all checks pass, perform a careful test drive and recheck all connections afterward.
    ⚠️If ANY fuel smell or visible leak is detected, immediately shut off the engine and disconnect the battery. Do not attempt to drive. Identify and correct the leak before proceeding.

Reassembly

1. Ensure all fuel line connections are fully engaged and locked with new O-rings installed
2. Verify fuel pump lock ring is torqued to specification
3. Confirm access cover screws are properly torqued
4. Ensure rear seat cushion is securely clipped in place
5. Verify no tools or parts are left in vehicle

Verification

• Turn ignition to ON position (engine off) and listen for fuel pump operation for 2-3 seconds
• Visually inspect all fuel connections for leaks with ignition ON
• Start engine and verify smooth idle with no fuel smell or visible leaks
• Check for diagnostic trouble codes using OBD-II scanner - there should be no fuel system codes
• Test drive vehicle and verify normal acceleration and fuel delivery
• After test drive, recheck all fuel line connections and access cover area for any signs of leakage
• Monitor fuel gauge operation to ensure fuel level sender is functioning correctly

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