Replacing Fuel Pump In Toyota Yaris: Step-By-Step Guide

The fuel pump in a Toyota Yaris is responsible for delivering fuel from the tank to the carburettor or fuel injection mechanism. While fuel pumps are designed to last the lifetime of a vehicle, they can occasionally fail. Signs of failure include the engine stalling, a whirring sound coming from the fuel tank, or the engine not starting at all. If you suspect your fuel pump is faulty, it's best to consult a mechanic as soon as possible. While it is possible to replace the fuel pump yourself, it is not recommended due to the risk of fire. The cost of replacing a fuel pump varies depending on the age and model of your vehicle, but it can be expensive, with some estimates ranging from $611 to $1832.

Disconnecting the battery

To begin, locate the battery in the engine bay of your Toyota Yaris. The battery is typically located in the front of the vehicle, near the fender or firewall. Once you have located the battery, look for the negative terminal, which is usually identified by a black cable and a "-" symbol. If you are unsure, refer to your owner's manual for the exact location and appearance of the battery terminal.

Before proceeding, ensure you are wearing protective gear, such as gloves and eye protection, to safeguard against any electrical hazards or battery acid. It is also recommended to have a set of tools ready, including a wrench or socket that fits the battery terminal.

Now, use your tool to loosen the nut or bolt that secures the negative battery cable. You may need to hold the battery terminal with one hand while turning the wrench or socket with the other. Be careful not to drop the nut or bolt into the engine bay, as it may be difficult to retrieve. Once the connection is loose, carefully remove the cable from the battery terminal. Ensure that the cable does not touch any metal parts of the car, as this could cause a short circuit.

At this point, the battery is disconnected, and you can proceed with the next steps of accessing and replacing the fuel pump. Remember to exercise caution when working with the fuel system and refer to a professional mechanic or repair manual for detailed instructions specific to your vehicle's make and model.

Removing the fuel tank access cover

To remove the fuel tank access cover of a Toyota Yaris, start by disconnecting the battery negative lead and folding the rear seat forwards or removing it. Next, lift up the carpet and pry up the access cover to reveal the unit. Be sure to disconnect the wiring plug and fuel supply pipe from the top of the unit, being cautious of any fuel spillage.

Now, remove the evaporative emissions connector by squeezing the tabs together and pulling it off. Unscrew and remove the mounting plate or loosen the lock ring, depending on the model of your Yaris.

Finally, carefully lift out the fuel pump/fuel level sensor, being careful not to damage the pump filter or bend the fuel level sensor float arm.

It is important to note that working with the fuel system is dangerous, and there is a risk of fire. Therefore, it is recommended to let a repair shop handle this job unless you are very experienced in auto repair.

Replacing the pump and pre-pump filter screen

To replace the fuel pump and pre-pump filter screen in a Toyota Yaris, you'll first need to disconnect the battery to reduce the chance of a fire.

For pumps inside the fuel tank, there will usually be an access cover that needs to be removed. With the cover off, you can replace the pump and pre-pump filter screen. In some cases, you will need to drain the fuel before removing the access panel.

When the pump is outside the tank, disconnect the fuel lines, remove the pump, and install the new one. Once the pump is replaced, check for any fuel leaks and ensure the problem is solved.

It is recommended that the fuel filters are replaced at the same time as the fuel pump. This also applies to the intake screen for in-tank fuel pumps. On some vehicles, the fuel pump relay is known to fail, so it is good practice to replace the relay when the pump is replaced.

Step 1: Disconnect the battery

Disconnect the battery to reduce the risk of fire.

Step 2: Remove the access cover

For pumps inside the fuel tank, locate and remove the access cover.

Step 3: Drain fuel (if necessary)

If there is fuel in the tank, you may need to drain it before proceeding.

Step 4: Replace the pump and filter screen

With the access cover removed, replace the faulty pump and the pre-pump filter screen.

Step 5: Install the new pump

If the pump is outside the fuel tank, disconnect the fuel lines and remove the old pump. Then, install the new pump.

Step 6: Check for leaks

Once the new pump is installed, check the area for any fuel leaks and ensure that the issue has been resolved.

Step 7: Replace fuel filters (recommended)

It is recommended to replace the fuel filters at the same time as the fuel pump.

Step 8: Replace the fuel pump relay (if necessary)

On some Toyota Yaris models, the fuel pump relay may fail, so it is a good idea to replace it when you replace the pump.

Please note that working with the fuel system can be dangerous, so it is important to take all necessary precautions to avoid the risk of fire.

Checking for leaks and proper function

To check for leaks and proper function of the fuel pump on a Toyota Yaris, you can perform the following steps:

Checking for Fuel Leaks

• Ensure that the ignition is off and that you have disconnected the GTS from the DLC3.
• Check for any fuel leaks from the fuel system, especially after performing maintenance or repairs.
• If there is a fuel leak, repair or replace the necessary parts.
• Reconnect the GTS to the DLC3 and turn the ignition to the "ON" position without starting the engine.
• Turn on the GTS and enter the "Powertrain/Engine/Active Test/Activate the Circuit Relay" menu.
• Measure the fuel pressure and ensure it is within the standard range of 280 to 664 kPa.
• If the fuel pressure is below the standard range, inspect the fuel hoses, connections, fuel pump, fuel filter, and fuel main valve assembly for any issues.
• Start the engine and measure the fuel pressure at idle, ensuring it remains within the standard range.
• Stop the engine and check that the fuel pressure holds for at least 5 minutes.
• If the fuel pressure drops, inspect the fuel pump, fuel main valve assembly, and port fuel injector assemblies for potential issues.

Checking Fuel Pump Operation

• Connect the GTS to the DLC3 and turn the ignition switch to the "ON" position without starting the engine.
• Turn on the GTS and enter the "Powertrain/Engine/Active Test" menu to activate the circuit relay.
• Check for pressure in the fuel tube sub-assembly and listen for sounds of fuel flowing from the fuel tank assembly.
• If no sounds are heard, inspect the relay, fuel pump, ECM, and wiring connectors for potential issues.

General Troubleshooting Tips

• If you notice any of the following issues, it could indicate a problem with your fuel pump:
• A whining or whirring noise coming from the fuel tank area
• Engine stalling or struggling to start
• Lack of power while driving or accelerating
• Engine sputtering or cutting out at high speeds
• Long cranking time before the engine starts
• Check engine light is on, especially with code P0087 indicating low fuel pressure
• If you suspect a fuel pump issue, it is recommended to have it checked by a professional mechanic or perform diagnostic testing:
• Use an OBD II scanner to check for relevant error codes
• Use a fuel pressure gauge to measure fuel pressure
• Inspect the fuel filter for blockages or debris
• Examine the fuel lines and connections for leaks or damage

Replacing the fuel filter and intake screen

To replace the fuel filter and intake screen in a Toyota Yaris, you'll first need to access the fuel pump, which is located under the back seat cushion. Start by disconnecting the shoulder belt from the lower buckle and setting it aside. Then, you can pry up the front of the seat cushion using a pry bar or large flat screwdriver. Once the clips on either side of the seat pop out, lift the front of the seat up and disconnect it from the hook at the back.

With the seat cushion removed, you'll see the access cover for the fuel pump. Clean the area and carefully pry up the cover, being careful not to damage it as it is held down by a sticky substance. Remove the cover, then unclip the electrical connection and remove it from the vehicle. Set the wiring aside.

Before removing the fuel pump assembly, depressurize the fuel line by attempting to start the engine, which will sputter and die. Once depressurized, disconnect the fuel lines and wrap the ends to prevent leaks.

Now, you can remove the entire fuel pump assembly. Spray some lubricant around the top edge of the retainer ring to help loosen it. Use a universal fuel pump retainer ring removal tool to undo the ring—do not attempt this without the tool. You may need an extra pair of hands to keep the tool from slipping off the ribs while you loosen the ring with a torque wrench.

With the retainer ring removed, lift the fuel pump assembly out of the tank, being careful not to damage the float/fuel level sender unit. Place the assembly in a container and drain the excess gasoline.

To access the fuel filter and intake screen, you'll need to disassemble the pump assembly. Begin by disconnecting the electrical connection from the bottom of the plug and removing the fuel line from the nipple on the housing. Cut the fuel line with a razor knife if necessary. Then, undo the clip holding the pump/filter assembly and remove it from the housing.

You'll now see the intake screen at the bottom of the pump. Gently pry apart the clips holding the retainer in place and remove it from the bottom of the filter. Then, you can slide the pump out of the filter assembly.

At this point, you can replace the intake screen and install a new fuel filter. Reassemble the pump assembly, ensuring all components are clean and properly seated. Reinstall the assembly in the fuel tank, making sure it is lined up properly and the O-ring is centred to avoid leaks. Tighten the retainer ring and reattach the fuel lines and electrical connections.

Finally, replace the access cover using silicone and reinstall the back seat cushion.

Frequently asked questions