2005 Toyota MR2 C65MFACTORY OEM SERVICE PROCEDURE

Fuel Pump: Replacement

CAUTION: Do not smoke or work near an open flame when working on the fuel pump.
  1. REMOVE LUGGAGE COMPARTMENT BOX (See  REMOVAL  ) 
  2. REMOVE FLOOR SERVICE HOLE COVER 
  3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 
  4. DISCONNECT VAPOR PRESSURE SENSOR CONNECTOR 
    1. Remove the 2 bolts and No. 3 fuel tank protector.
    2. Disconnect the sensor connector.
    Fig 1: Identifying Fuel Tank Protector Bolts
    G02630976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT FUEL TANK MAIN TUBE AND EMISSION TUBE 
    CAUTION:
    • Disconnect the fuel tube connector (quick type) observing the precaution (See SFI SYSTEM ).
    • As there is retained pressure in the fuel line, prevent if from splashing inside the luggage compartment.
    1. Remove the tube joint clip and disconnect the main tube.
    2. Disconnect the emission tube.
    Fig 2: Removing Tube Joint Clip
    G02630977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK 
    1. Remove the 6 bolts and fuel tank vent tube set plate.
    2. Remove the fuel pump and sender gauge assembly.
      NOTE:
      • Do not damage the fuel suction filter.
      • Be careful that the arm of the sender gauge is not bent.
    3. Remove the gasket from the pump and sender gauge assembly.
    Fig 3: Identifying Fuel Tank Vent Tube Set Plate Bolts
    G02630978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL SUCTION SUPPORT 
    1. Using a screwdriver, pry out the fuel suction support.
      NOTE: Be careful not to damage the suction support.
    2. Remove the rubber cushion.
    Fig 4: Removing Fuel Suction Support Using A Screwdriver
    G02630979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL SUCTION PLATE 
    1. Disconnect the fuel sender gauge connector and ground plate.
      Fig 5: Disconnecting Fuel Sender Gauge Connector And Ground Plate
      G02630980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers, pry out the fuel suction plate.
      NOTE: Be careful not to damage the suction support and suction plate.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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