Fuel Pump Filter Replacement

[chap79]

At 210k I decided that it was probably time to replace the fuel pump filter. This is a job.

Here are the parts I needed for my '97.

Filter, Fuel pump 23217-16490
Gasket, Fuel junction 77169-60010
Clip, Fuel filter 23219-03010
Gasket 90430-12026 x2

Tools needed:

Ratchet and small extension
8mm, 14mm, and 17mm sockets
Philips screw driver
Small flat head screw driver

1. Remove the second row seats and door scuff plates.

2. Fold back the carpet to access the Floor Service Hole Cover.

3. Remove the cover (3 screws).

4. Clean the area so that no dirt or debris falls in the fuel tank.

5. Disconnect the fuel pipe and hose from the fuel pump bracket.

6. Remove the union bolt and gaskets, and disconnect the outlet pipe from the pump bracket.

7. Disconnect the return hose from the pump bracket.

8. Remove the 8 bolts, remove the fuel pump assembly.

9. Gently pry the fuel pump filter clip off the bottom of the fuel pump with a small flat head screw driver. Gently pry off the filter .

10. Remove the gasket from the fuel pump bracket.

11. Installation is in the reverse order of removal .


Edit: Added additional part numbers.

 

[suadero]

Nice write up. I have this stuff but want to do it at the same time as the fuel filter...which means when my arms grow about a foot but shrink in diameter.

 

[baldilocks]

A new pick up sock is among the parts I have waiting to be installed. I found your write up to be helpful.

 

[chap79]

The only real "hint" I can offer is that I used a 6" extension to tap the filter and clip on to the pump. It is a really straight forward replacement, hope this helps someone.

 

[sleepycruiser]

I wish all help threads were like this complete with part numbers and pics. It really helps those like me who wouldn't know anything about it otherwise. Well done!

 

[OGBeno]

You also need 90430-12026 x2 -- gaskets for the banjo bolt.

Nice write up.

 

[on3i11s]

Awesome write up. Bookmarking this thread for future reference!

 

[chap79]

You also need 90430-12026 x2 -- gaskets for the banjo bolt.

Nice write up.

I thought about this as I was looking at the banjo bolt, similar to the fuel rail, I even considered using some of the same brass washers I had left over from the last HG job I did. Too bad you were on sabbatical when I ordered parts .

 

[alia176]

When I did this project years ago, I cut out a half moon hole on the carpet over the access hatch. That way, no more messing with the carpet for fuel pump related project, just lift up the flap and access the hatch. Mainly did it just in case I'm out wheeling and need to access the pump. I wanted to avoid emptying out the entire second row for pump access.

 

[melmwood]

First, thanks @chap79 for the write-up. Your post, along with this one (Olde North State Cruisers), helped a "visual learner" like me a ton. I was nervous about making sure none of the connections and metal parts of the pump were damaged or bent. But I got it done without so much as an unneeded scratch on the cover. So thanks. My added remarks for this job:

I'm guessing I learned a good lesson today about working on the fuel system right after a decent (~20 mile) drive: As soon as I loosened the banjo bolt gas sprayed out happily. Seems I had some decent pressure built up. Once it subsided, I just wiped her all down and proceeded along with no issues. So unsure what the rule is, if any, on touching the fuel system and avoiding pressure sprays like I experienced. Next time I touch it (fuel filter coming up here shortly) I guess I'll just tackle it in the morning before driving it that day. Or maybe just removing the gas cap would have been sufficient...

 

[jonheld]

So unsure what the rule is, if any, on touching the fuel system and avoiding pressure sprays like I experienced.

Start the engine and remove the connector on the fuel pump or simply pull the FP relay or circuit opening relay and let the engine stall. That will minimize the pressure in the fuel line.
Remove the fuel fill cap. That will remove the pressure in the tank.

 

[melmwood]

Adding that to the knowledge bank @jonheld . I will say that my way removes the need to spray any sort of cleaner on the top of the fuel pump before removal - wiping up the gas cleans it like a champ!

 

[enox]

Thanks for this write up, this came in handy! Tackling the fuel filter tomorrow. I noticed my low fuel light wasn't working, when I removed the pump assembly and plugged it back in (played with the float and got the light to come on) reinstalled now I've gotta burn approx 20Gal before finding out if the dummy light works...

 

[mtrdud]

Does anyone know the part number for these OEM clamps pictured?
@Onur, @cDan.

 

[OGBeno]

90467-12067

 

[fjbj40]

Float has nothing to do with the low level light.

That little round metal thing next to the pump is called a thermistor, that is what turns on the low level light.

As the fuel level goes below this it actually warms up and closed the circuit to turn on the light.

 

[BillyGoatMTB]

Great write up and conversation,

Anyone have any thoughts on replacing the fuel pump while in there? Im planning to do the strainer but its all so easy to get to i am trying to justify spending the extra $250 on the pump. I have 310k and the PO performed no maintenance, so i have been knocking out my todo list regularly.

I have noticed what sounds a bit like an electric speaker whine coming from what might be the fuel pump area but i need to see if thats the sound. only under acceleration above 2k and constant on the highway.

Rock on MUD

 

[baldilocks]

What’s peace of mind worth? For my own peace of mind and cruiser reliability the cost is definitely justified. How much of my trip do I want to spend broken down? None. While your touching absolutely every square inch of your rig you learn about it so if there is a breakdown you know what you’ve got.

 

[secretasiansam]

Great write up and conversation,

Anyone have any thoughts on replacing the fuel pump while in there? Im planning to do the strainer but its all so easy to get to i am trying to justify spending the extra $250 on the pump. I have 310k and the PO performed no maintenance, so i have been knocking out my todo list regularly.

I have noticed what sounds a bit like an electric speaker whine coming from what might be the fuel pump area but i need to see if thats the sound. only under acceleration above 2k and constant on the highway.

Rock on MUD

I'm replacing my perfectly functional fuel pump soon. I only paid $110 at densoparts.com?
I travel mostly alone. It's worth the piece of mind to me.

 

[Kernal]

Replace while it's in front of you or wait until it dies, although 25years seems like a good (enough) life for an elecric fuel pump.

FWIW I replaced the pump on my 96 FZJ80 at ~330,000 when the engine started to develop a very slight hesitation on hard acceleration. The problem went away with a new Denso aftermarket pump (Rock Auto) and OEM sock. Now at 370,000 miles with no issues currently related to fuel.