Fuel Pump: Service and Repair
REPLACEMENTCAUTION: Do not smoke or work near an open frame when working on the fuel pump.
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. DRAIN FUEL
4. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSEMBLY LH (SEPARATED TYPE REAR SEAT)
5. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY (FIXED TYPE REAR SEAT)
6. REMOVE REAR FLOOR SERVICE HOLE COVER NO.2
a. Remove the 3 cap nuts and service hole cover.
7. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
NOTE:
- These procedures should be performed with the fuel tank less than 1/4 full.
- Check for dirt contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools in these procedures.
- Do not forcefully bend or twist the nylon tube.
- Check for dirt contamination on the pipe seal surface. Clean if necessary.
- Put the pipe and connector ends in vinyl bags to prevent damage and dirt contamination.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
a. Remove the tube joint clip.
b. Pull out the fuel main tube.
c. Plug the port of the fuel suction plate with a clean rubber cap.
8. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and set plate.
9. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY
a. Lift up the fuel pump and sender gauge. Disconnect the fuel sub-suction hose from the fuel return jet tube and remove the fuel pump, sender gauge and gasket.
CAUTION:
- Do not damage the fuel pump filter.
- Be careful not to bend the arm of the sender gauge.
10. REMOVE FUEL SUCTION SUPPORT NO.2
a. Using 2 screwdrivers, disconnect the 3 snap claws from the claw holes and remove the fuel suction support.
NOTE: Be careful not to damage the suction support and fuel filter.
11. REMOVE FUEL PUMP CUSHION RUBBER
12. REMOVE FUEL PRESSURE W/JET PUMP REGULATOR ASSEMBLY
a. Disconnect the fuel return jet tube from the clamp of the fuel filter.
b. Pull out the fuel pressure regulator from the fuel filter, and remove the fuel pressure regulator and fuel return jet tube.
c. Remove the O-ring from the fuel pressure regulator.
13. REMOVE FUEL SUCTION PLATE W/SENDER GAUGE
a. Using 2 screwdrivers, disconnect the 4 snap claws from the claw holes and remove the fuel filter.
NOTE: Be careful not to damage the filter assembly and suction plate.
b. Disconnect the fuel pump connector.
c. Remove the O-ring from the fuel port of the fuel suction plate.
14. REMOVE FUEL PUMP FILTER
a. Remove the clip and filter.
15. REMOVE FUEL PUMP ASSEMBLY
a. Pull out the fuel pump.
b. Remove the seal and spacer from the fuel pump.
16. INSTALL FUEL PUMP ASSEMBLY
a. Apply some gasoline to a new seal.
b. Install the spacer and a new seal to the fuel pump.
c. Push in the fuel pump.
17. INSTALL FUEL PUMP FILTER
a. Install the filter with a new clip.
18. INSTALL FUEL SUCTION PLATE W/SENDER GAUGE
a. Apply a light coat of gasoline to a new O-ring, and install it to the fuel port of the fuel suction plate.
b. Connect the fuel pump connector.
c. Push the fuel filter, and attach the 4 snap claws to the claw holes.
19. INSTALL FUEL PRESSURE W/JET PUMP REGULATOR ASSEMBLY
a. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
b. Push in the fuel pressure regulator to the fuel filter.
c. Check that the fuel pressure regulator rotates smoothly.
If it does not rotates smoothly, the O-ring may be pinched. Remove the fuel pressure regulator and perform steps (b) and (c).
d. Connect the fuel return jet tube to the clamp of the fuel filter.
20. INSTALL FUEL PUMP CUSHION RUBBER
21. INSTALL FUEL SUCTION SUPPORT NO.2
a. Push the fuel suction support, and attach the 3 snap claws to the claw holes.
22. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY
a. Install a new gasket to the fuel suction plate.
b. Connect the fuel sub-suction hose to the fuel return jet tube.
c. Attach the fuel pump and sender gauge to the fuel tank.
23. INSTALL FUEL TANK VENT TUBE SET PLATE
a. Install the set plate with the 8 bolts.
Torque: 6.0 N.m (61 kgf.cm, 52 in.lbf)
24. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Attach the fuel tube connector to the port of the fuel suction plate.
b. Install the tube joint clip.
25. INSTALL REAR FLOOR SERVICE HOLE COVER NO.2
Install the service hole cover with the 3 cap nuts.
26. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY (FIXED TYPE REAR SEAT)
27. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSEMBLY LH (SEPARATED TYPE REAR SEAT)
28. ADD FUEL
29. CONNECT BATTERY NEGATIVE TERMINAL
NOTE: When disconnecting the negative (-) battery terminal, initialize the following system(s) after the terminal is reconnected.
30. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS