1. Welcome to Tacoma World!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

Replacing the Fuel Pump, A How To...

Discussion in '1st Gen. Tacomas (1995-2004)' started by Digiratus, Mar 26, 2020.

  1. Mar 26, 2020 at 7:21 PM
    #1
    Digiratus

    Digiratus [OP] Adventurer

    Joined:
    Mar 26, 2010
    Member:
    #34006
    Messages:
    20,004
    Gender:
    Male
    First Name:
    Mike
    Roaming the PNW
    Vehicle:
    The RedHead
    2002 XtraCab TRD 4x4 v6 Auto Trans With Lots of Mods ADS COs w/Compression Adjusters Camburg Uniball UCAs Whiteline Lower Control Arm Bushings Kartek 7" Limit Straps Plastics Guy Front Bumpstops Custom Alcan Springs +800 lbs +3" ADS 10" Stroke Triple Bypass w/Resi Rear Shocks Custom Rear Shock Relocate All-Pro U-bolt Flip w/Timbren Bumpstops 4.88 Nitro Gears ARB Front Locker ARB Twin Compressor Gunmetal 16x8 SCS Ray10s 255/85r16 Maxxis Bighorns Limited Edition (Relentless) Elite Front Bumper Smittybilt X2O 10K Winch Diode Dynamics SS3 Sport Selective Yellow Fog Lights in the Bumper Diode Dynamics SS3 Pro 4,000K Driving Lights on the Bumper Mini D2S Projectors XB35 Ballasts + 4500K Bulbs Badland Sliders FrankenFab Tire Carrier Swingout bumper w/kitchen BudBuilt Front & Bellypan Skids BAMF Rear Diff Skid Whynter 65 qt. Fridge/Freezer CVT Mt Bachelor RTT Badland Custom Bed Rack GM 140 amp alternator Dual Northstar 24F AGM batteries BlueSea 7622 ML-ACR Battery controller Peak DBI Dual Battery Voltage Monitor Doug Thorley Headers Magnaflow 18" Muffler w/upstream CAT delete 13WL Brake Calipers Braided Steel Brake Lines AFE Pro Dry S air filter ScanGauge II OBDII Scanner Kenwood TM-71A Dual Band Ham Radio Larson 70CM/2M Antenna Uniden 520xl CB radio 3' Firestik Adjustable tip antenna Pioneer DEH-P9400BH HU Alpine Amps & Type R components (F) and coaxials (R) Wet Okole Seat Covers Weathertech Digital Liners Deck Plate Mod 1" Diff Drop Carrier Bearing Drop
    I did this on my '02 XtraCab v6 while I had the bed off. I figured now was the time at 195K miles. I used an Aeromotive Stealth pump. Model #11542, with a new OEM gasket for the hatch.

    Gasket, Fuel Suction 77169-04010

    Aeromotive 11542
    https://www.amazon.com/Aeromotive-11542-Stealth-Offset-Inline/dp/B012HRFKTE

    Start by removing the fuel lines.

    IMG_20200322_152124.jpg

    The one on the right with the weird looking fitting was kicking my ass.

    IMG_20200322_152148.jpg

    I could not figure it out until my friend Zane @Speedytech7 told me it requires a special tool to get it to release.

    Went to the 'Zone' and rented one of these kits.

    IMG_20200322_165956.jpg

    Fitting popped right off after that.

    Next step was to undo the two clips on the top of the hatch.

    IMG_20200322_153809.jpg

    I always struggle with these type of clips. Until you get it apart the first time, it can some times be confusing how the things come apart. I swear, there are no two alike on my entire truck. Plus add in the 18 years of crud and grime and Moab...:p Well at least I got them apart without breaking them.

    As you can see from this last photo, there is a lot of dirt on the hatch and on the top of the fuel tank. I used an air hose to blow off anything loose so there was no chance of anything getting into the tank after opening it up.

    Next step is the remove the 8 bolts that hold the hatch to the tank. Once those are off, the entire fuel pump assembly bracket pulls straight up and out of the tank.

    I think this is by far the cleanest part on my entire truck.

    IMG_20200322_173945.jpg

    The old and the new. If you replace with aftermarket like I did, the original power plug will have to be swapped over to the new pump.

    IMG_20200324_160438.jpg

    Also, since the Aeromotive pump is a little longer that the OEM unit, so the hard line on the bracket that feeds out through the hatch has to be shortened a little for it all to fit together correctly.

    New and old pump.

    IMG_20200324_163707.jpg

    I used a small pipe cutter to shorten the hard line.

    IMG_20200324_175401.jpg

    I cut off about 3/8" but a 1/4" would have been plenty.

    IMG_20200324_175930.jpg

    Here is how it sits after trimming.

    IMG_20200324_180231.jpg

    After rewiring the power connector it was time to reinstall the new pump onto the bracket assembly.

    IMG_20200324_175344.jpg
    IMG_20200324_181748.jpg
    IMG_20200324_181848.jpg
    IMG_20200324_184708.jpg
    IMG_20200324_181132.jpg

    This ended up being a fun little project. I hope this write up is helpful. Let me know if you have any questions.

    All buttoned back up and ready for another 200K.

    IMG_20200324_190022.jpg
     
    Last edited: Mar 26, 2020
    GQ7227, nagorb, Phessor and 2 others like this.
  2. Mar 26, 2020 at 7:23 PM
    #2
    Speedytech7

    Speedytech7 Toyota Cult Ombudsman

    Joined:
    Feb 20, 2014
    Member:
    #123587
    Messages:
    34,362
    Gender:
    Male
    First Name:
    Zane
    Spokane, WA
    Vehicle:
    93 Land Cruiser & 96 Tacoma V6 4WD
    I've done a mod or two
    Well done, I liked the part where you changed the fuel pump :p
     
    b_r_o and Digiratus [OP] like this.
  3. Mar 26, 2020 at 8:04 PM
    #3
    jubei

    jubei wishes he was in Moab right now.

    Joined:
    Mar 17, 2016
    Member:
    #181549
    Messages:
    4,746
    Gender:
    Male
    First Name:
    Jason
    NoCo
    Vehicle:
    White 2002 XC TRD and Yellow 1971 JEEP CJ5
    Stuff. Also things.
    Very nice, Mike!
     
    Digiratus [OP] likes this.
  4. Mar 26, 2020 at 8:44 PM
    #4
    Glamisman

    Glamisman Well-Known Member

    Joined:
    Oct 22, 2016
    Member:
    #200436
    Messages:
    3,103
    Gender:
    Male
    Excellent write up. I hope that the fuel line between the pump and the outlet is a submersible fuel line and not just fuel line.
     
  5. Mar 26, 2020 at 9:00 PM
    #5
    Speedytech7

    Speedytech7 Toyota Cult Ombudsman

    Joined:
    Feb 20, 2014
    Member:
    #123587
    Messages:
    34,362
    Gender:
    Male
    First Name:
    Zane
    Spokane, WA
    Vehicle:
    93 Land Cruiser & 96 Tacoma V6 4WD
    I've done a mod or two
    Comes with the pump
     
    b_r_o and Digiratus [OP] like this.
  6. Mar 26, 2020 at 9:04 PM
    #6
    Digiratus

    Digiratus [OP] Adventurer

    Joined:
    Mar 26, 2010
    Member:
    #34006
    Messages:
    20,004
    Gender:
    Male
    First Name:
    Mike
    Roaming the PNW
    Vehicle:
    The RedHead
    2002 XtraCab TRD 4x4 v6 Auto Trans With Lots of Mods ADS COs w/Compression Adjusters Camburg Uniball UCAs Whiteline Lower Control Arm Bushings Kartek 7" Limit Straps Plastics Guy Front Bumpstops Custom Alcan Springs +800 lbs +3" ADS 10" Stroke Triple Bypass w/Resi Rear Shocks Custom Rear Shock Relocate All-Pro U-bolt Flip w/Timbren Bumpstops 4.88 Nitro Gears ARB Front Locker ARB Twin Compressor Gunmetal 16x8 SCS Ray10s 255/85r16 Maxxis Bighorns Limited Edition (Relentless) Elite Front Bumper Smittybilt X2O 10K Winch Diode Dynamics SS3 Sport Selective Yellow Fog Lights in the Bumper Diode Dynamics SS3 Pro 4,000K Driving Lights on the Bumper Mini D2S Projectors XB35 Ballasts + 4500K Bulbs Badland Sliders FrankenFab Tire Carrier Swingout bumper w/kitchen BudBuilt Front & Bellypan Skids BAMF Rear Diff Skid Whynter 65 qt. Fridge/Freezer CVT Mt Bachelor RTT Badland Custom Bed Rack GM 140 amp alternator Dual Northstar 24F AGM batteries BlueSea 7622 ML-ACR Battery controller Peak DBI Dual Battery Voltage Monitor Doug Thorley Headers Magnaflow 18" Muffler w/upstream CAT delete 13WL Brake Calipers Braided Steel Brake Lines AFE Pro Dry S air filter ScanGauge II OBDII Scanner Kenwood TM-71A Dual Band Ham Radio Larson 70CM/2M Antenna Uniden 520xl CB radio 3' Firestik Adjustable tip antenna Pioneer DEH-P9400BH HU Alpine Amps & Type R components (F) and coaxials (R) Wet Okole Seat Covers Weathertech Digital Liners Deck Plate Mod 1" Diff Drop Carrier Bearing Drop
    Yeah, The Aeromotive kit comes with everything that is need to make the swap.
     
    Phessor likes this.
  7. Mar 31, 2020 at 9:00 AM
    #7
    Tacoscar-the-grouch

    Tacoscar-the-grouch Well-Known Member

    Joined:
    Mar 22, 2019
    Member:
    #287551
    Messages:
    300
    Gender:
    Male
    First Name:
    Josh
    North Idaho
    Vehicle:
    2001 Reg. Cab Tacoma
    OME kit 4.56's 235/85/16
    Is there any procedure to bleed the fuel system after opening the lines? Or do you just crank it over a few times to purge the air on first start?

    Thanks!

    I have my tank out right now doing some frame restoration and suspension. About ready to reinstall though. Also with that weird fuel clip, I was able to disconnect it using some small Flathead screwdrivers instead of the fancy tool kit. It'll do in a pinch, but I'd have used the proper tool if I knew I needed it before tearing into the truck.
     
  8. Mar 31, 2020 at 9:01 PM
    #8
    Digiratus

    Digiratus [OP] Adventurer

    Joined:
    Mar 26, 2010
    Member:
    #34006
    Messages:
    20,004
    Gender:
    Male
    First Name:
    Mike
    Roaming the PNW
    Vehicle:
    The RedHead
    2002 XtraCab TRD 4x4 v6 Auto Trans With Lots of Mods ADS COs w/Compression Adjusters Camburg Uniball UCAs Whiteline Lower Control Arm Bushings Kartek 7" Limit Straps Plastics Guy Front Bumpstops Custom Alcan Springs +800 lbs +3" ADS 10" Stroke Triple Bypass w/Resi Rear Shocks Custom Rear Shock Relocate All-Pro U-bolt Flip w/Timbren Bumpstops 4.88 Nitro Gears ARB Front Locker ARB Twin Compressor Gunmetal 16x8 SCS Ray10s 255/85r16 Maxxis Bighorns Limited Edition (Relentless) Elite Front Bumper Smittybilt X2O 10K Winch Diode Dynamics SS3 Sport Selective Yellow Fog Lights in the Bumper Diode Dynamics SS3 Pro 4,000K Driving Lights on the Bumper Mini D2S Projectors XB35 Ballasts + 4500K Bulbs Badland Sliders FrankenFab Tire Carrier Swingout bumper w/kitchen BudBuilt Front & Bellypan Skids BAMF Rear Diff Skid Whynter 65 qt. Fridge/Freezer CVT Mt Bachelor RTT Badland Custom Bed Rack GM 140 amp alternator Dual Northstar 24F AGM batteries BlueSea 7622 ML-ACR Battery controller Peak DBI Dual Battery Voltage Monitor Doug Thorley Headers Magnaflow 18" Muffler w/upstream CAT delete 13WL Brake Calipers Braided Steel Brake Lines AFE Pro Dry S air filter ScanGauge II OBDII Scanner Kenwood TM-71A Dual Band Ham Radio Larson 70CM/2M Antenna Uniden 520xl CB radio 3' Firestik Adjustable tip antenna Pioneer DEH-P9400BH HU Alpine Amps & Type R components (F) and coaxials (R) Wet Okole Seat Covers Weathertech Digital Liners Deck Plate Mod 1" Diff Drop Carrier Bearing Drop
    I didn't do anything special. Just let it crank over til it fired. Wasn't more than 5-10 seconds of cranking.
     
    Tacoscar-the-grouch and GQ7227 like this.
  9. Mar 31, 2020 at 9:53 PM
    #9
    CrippledOldMan

    CrippledOldMan Well-Known Member

    Joined:
    Jan 25, 2019
    Member:
    #280651
    Messages:
    1,126
    Gender:
    Male
    First Name:
    David
    Salisbury North Carolina
    Vehicle:
    2003 TRD Crew Cab
    None
    In the last photo what are the 3 items showing on the top of the gas tank. The Fuel Pump is on the left. what is the part in the middle, and the one of the far right. Thanks from all of us, that haven't done this job yet.
     
    GQ7227 likes this.
  10. Mar 31, 2020 at 10:36 PM
    #10
    Digiratus

    Digiratus [OP] Adventurer

    Joined:
    Mar 26, 2010
    Member:
    #34006
    Messages:
    20,004
    Gender:
    Male
    First Name:
    Mike
    Roaming the PNW
    Vehicle:
    The RedHead
    2002 XtraCab TRD 4x4 v6 Auto Trans With Lots of Mods ADS COs w/Compression Adjusters Camburg Uniball UCAs Whiteline Lower Control Arm Bushings Kartek 7" Limit Straps Plastics Guy Front Bumpstops Custom Alcan Springs +800 lbs +3" ADS 10" Stroke Triple Bypass w/Resi Rear Shocks Custom Rear Shock Relocate All-Pro U-bolt Flip w/Timbren Bumpstops 4.88 Nitro Gears ARB Front Locker ARB Twin Compressor Gunmetal 16x8 SCS Ray10s 255/85r16 Maxxis Bighorns Limited Edition (Relentless) Elite Front Bumper Smittybilt X2O 10K Winch Diode Dynamics SS3 Sport Selective Yellow Fog Lights in the Bumper Diode Dynamics SS3 Pro 4,000K Driving Lights on the Bumper Mini D2S Projectors XB35 Ballasts + 4500K Bulbs Badland Sliders FrankenFab Tire Carrier Swingout bumper w/kitchen BudBuilt Front & Bellypan Skids BAMF Rear Diff Skid Whynter 65 qt. Fridge/Freezer CVT Mt Bachelor RTT Badland Custom Bed Rack GM 140 amp alternator Dual Northstar 24F AGM batteries BlueSea 7622 ML-ACR Battery controller Peak DBI Dual Battery Voltage Monitor Doug Thorley Headers Magnaflow 18" Muffler w/upstream CAT delete 13WL Brake Calipers Braided Steel Brake Lines AFE Pro Dry S air filter ScanGauge II OBDII Scanner Kenwood TM-71A Dual Band Ham Radio Larson 70CM/2M Antenna Uniden 520xl CB radio 3' Firestik Adjustable tip antenna Pioneer DEH-P9400BH HU Alpine Amps & Type R components (F) and coaxials (R) Wet Okole Seat Covers Weathertech Digital Liners Deck Plate Mod 1" Diff Drop Carrier Bearing Drop
    The one in the middle is some sort of vent. I have no idea what the one on the right is.
     

    Attached Files:

    GQ7227 likes this.
  11. Apr 2, 2020 at 9:45 AM
    #11
    Tacoscar-the-grouch

    Tacoscar-the-grouch Well-Known Member

    Joined:
    Mar 22, 2019
    Member:
    #287551
    Messages:
    300
    Gender:
    Male
    First Name:
    Josh
    North Idaho
    Vehicle:
    2001 Reg. Cab Tacoma
    OME kit 4.56's 235/85/16
    Thanks for the info @Digiratus, truck fired right up yesterday.

    My truck does not have this. It might be part of the evap system?
     
    Speedytech7 and Digiratus [OP] like this.

Products Discussed in

To Top