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Old 10-14-2023, 10:10 AM #1
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Dropping tank, easy to replace fuel pump?
Replacing the overfill check valve on my 2002. Should I order a new fuel pump and strainer while I’m at it? Is the fuel pump an easy replacement?
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Old 10-14-2023, 11:10 AM #2
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It wouldn't be a bad idea to replace the fuel pump and filter inside the tank. They have been known to fail which can leave you stranded. The hardest part is making all the disconnects to drop the tank. Once the tank is out, removing the fuel sending unit assembly is easy. Replacing the fuel pump and filter on the fuel sending unit assembly is also easy and straightforward.

You can use my video to learn how to do most of it. We don't show replacing the fuel pump, but it is very easy once you have the sending unit in your hands.

You should definitely replace the rubber gasket that seals the sending unit to the top of the tank. We have it linked in the video description.

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Old 10-14-2023, 11:21 AM #3
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Quote:
Originally Posted by mtbtim View Post
It wouldn't be a bad idea to replace the fuel pump and filter inside the tank. They have been known to fail which can leave you stranded. The hardest part is making all the disconnects to drop the tank. Once the tank is out, removing the fuel sending unit assembly is easy. Replacing the fuel pump and filter on the fuel sending unit assembly is also easy and straightforward.

You can use my video to learn how to do most of it. We don't show replacing the fuel pump, but it is very easy once you have the sending unit in your hands.

You should definitely replace the rubber gasket that seals the sending unit to the top of the tank. We have it linked in the video description.
Your video is literally bookmarked on my iPad for when I start the repair lol. Thanks for your channel and advice!
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Old 10-15-2023, 07:25 PM #4
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The fuel pump is very easy to replace once the tank is out. Japanese fuel pumps in general and Toyotas in particular don't fail very often. (probably have replaced under 5 Toyota fuel pumps in 39 years) Good idea to replace the rubber gasket and the strainer. Are you changing the check valve due to the vehicle being difficult to fill with gas? If so you probably need a new EVAP canister instead.
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Old 10-16-2023, 03:38 AM #5
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I have a 2001 2wd Auto SR5…

Make sure you have 2 pry bars handy when you remove the check valve. I wasted so much time tonight trying to find a “tool” for the job, before finally making a 10:30pm Walmart run to buy 2 24” pry bars. Also, the larger hose that runs from the check valve to the EVAP canister is a pain to get off without breaking…for me, anyway. Luckily, I had purchased a new one…so I was able to break the old connectors off and install a new hose. I also had to eventually drag my gf out to give me a hand, and extra set of hands goes a long way.

P# for the hose is…77404-35010
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Old 10-16-2023, 06:28 AM #6
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Quote:
Originally Posted by MaineRunna View Post
The fuel pump is very easy to replace once the tank is out. Japanese fuel pumps in general and Toyotas in particular don't fail very often. (probably have replaced under 5 Toyota fuel pumps in 39 years) Good idea to replace the rubber gasket and the strainer. Are you changing the check valve due to the vehicle being difficult to fill with gas? If so you probably need a new EVAP canister instead.
That’s exactly why I’m replacing the check valve. Also codes p0440, 0441, 0446. I didn’t know if it was the check valve or the canister so I chose the cheaper (higher labor) part. In addition, I unplugged the 1” plastic hose that runs from the valve to the canister and I still had the issue. My assumption was that is the sole hose responsible for venting and separating it from the canister would rule it out. Am I wrong? There’s also a small hose in the overfill check valve though that I didn’t disconnect, I’m not sure what it does.
Last edited by DWilliam; 10-16-2023 at 07:06 AM.
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Old 03-27-2024, 05:42 PM #7
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Quote:
Originally Posted by DWilliam View Post
That’s exactly why I’m replacing the check valve. Also codes p0440, 0441, 0446. I didn’t know if it was the check valve or the canister so I chose the cheaper (higher labor) part. In addition, I unplugged the 1” plastic hose that runs from the valve to the canister and I still had the issue. My assumption was that is the sole hose responsible for venting and separating it from the canister would rule it out. Am I wrong? There’s also a small hose in the overfill check valve though that I didn’t disconnect, I’m not sure what it does.
Did you end up having to replace the canister? I just dropped my tank yesterday to replace the valve for the same codes and I can't see anything wrong with it. Afraid I may have to get a charcoal can next. Waiting for a new vent hose to show up. Also ordered a new fuel pump before I put everything back together, figure might as well while it's out.
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