Toyota Harrier 2.4 AZ-FE (2004): Fuel Pump and Filter Assembly Replacement

Part numbers are from the manufacturer's original catalogue. Check them against your VIN before ordering.

• socket set and ratchet (for the cover bolts)
• low-range torque wrench
• thin-nose pliers
• screwdriver with electrical tape on the tip
• plastic bag
• container and rags
• fire extinguisher nearby

1. Park the vehicle on level ground, shut off the engine and remove any sources of ignition. Keep a fire extinguisher nearby, and do not smoke.
2. Remove the rear seat cushion. The mounting method depends on the seat type (fixed or with adjustable recline), so inspect the fasteners and remove them without yanking.
3. Remove the service access cover in the floor. The cover is stuck down with butyl tape, so separate it carefully when removing.
4. Relieve the fuel system pressure. Disconnect the fuel pump connector, start the engine and wait until it stalls on its own. Turn the ignition off, then crank the engine with the starter once more to confirm it does not start. A lean mixture trouble code may be stored as a result, and you will clear it later with a scan tool.
5. Open the fuel filler cap to release the pressure in the tank.
6. Disconnect the negative battery terminal.
7. Clean all dirt from around the fuel tube fitting. Any dirt that gets in will later keep the O-rings from sealing.
8. Cover the connection with a rag, since residual pressure remains in the line. Remove the retaining clip and disconnect the fuel tube from the module. Do not pry the connection with a tool, use only your hands. Do not kink or twist the nylon tube. If the connection is stuck, gently squeeze the tube and carefully rock it. Cover the disconnected fitting with a plastic bag.
9. Remove the 8 bolts of the module cover plate and mark the position of the plate relative to the tube.
10. Carefully lift the module out of the tank. Do not damage the pump strainer (filter screen) or bend the fuel level sender arm. Remove the old gasket, which is single-use.
11. Transfer to the new module whatever your design requires, and compare it with the old one for length and shape. If you are disassembling the pump separately, use new O-rings lightly lubricated with gasoline and a new retaining ring. Do not remove the pump strainer.
12. Install the new gasket and lower the module into the tank without damaging the level sender arm. Align the mark on the plate with the mark on the tube.
13. Tighten the 8 plate bolts to about 5.9 N·m (4.4 lb-ft), in a crisscross pattern and evenly. The torque is low, so do not overtighten.
14. Connect the fuel tube. Check that the connection and fitting are clean and free of scratches, and that they are seated fully. The clip must seat on the fitting's shoulder. Pull on the connection by hand to confirm it is locked.
15. Reconnect the negative battery terminal. With the pump connector still unplugged, repeat the leak check, then plug in the pump connector. Turn the ignition on for 2-3 seconds several times without starting the engine to build pressure, and inspect the connection and the plate for leaks.
16. Close the access panel with the cover on new butyl tape and install the rear seat cushion. Start the engine, let it run, and check once more for the smell of gasoline. Clear the codes with the scan tool.
17. For verification, if you have a pressure gauge: fuel pressure with the engine running should be about 304-343 kPa (3.1-3.5 kgf/cm2). Five minutes after the engine is stopped, it should remain no lower than 147 kPa.

• Working with gasoline is dangerous: sparks, open flames and smoking are not allowed, and you must work in a well-ventilated area
• Do not leave the fuel system open, and do not allow dirt into the connections
• If you have no experience working on fuel systems, leave the replacement to a repair shop
• Verify the details of the rear seat mounting and the connector locations on your Harrier during disassembly