Fuel Pump: Service and Repair

Fuel Pump Assy (4WD) Part 1:

Fuel Pump Assy (4WD) Part 2:

FUEL PUMP ASSY (4WD)
Removal & Installation and Disassembly & Reassembly







1. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY
Remove the 2 installing bolts of the rear seat cushion.







2. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear service hole cover.







b. Disconnect the fuel pump and vapor pressure sensor connector.

3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
Refer to Fuel Pressure Release.

a. Start the engine.
b. After the engine has stopped on the its own, turn the ignition switch to lock.







4. REMOVE FUEL TANK PROTECTOR NO.2
Remove the 3 bolts and fuel tank protector.







5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY
Remove the tube joint clip, and pull out the fuel tank main tube.

NOTE: Check if there is any dirt like mud around the fuel tube joint before this work and clean dirt away.
Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube joint and fuel suction plate.
Do not use any tool in this work.







Do not bend or twist the nylon tube by force.
After disconnecting, cover the fuel tube joint with a vinyl bag.
When the fuel tube joint and plug are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.







6. REMOVE FUEL TANK VENT TUBE SET PLATE
Remove the 5 bolts and fuel tank vent tube set plate.







7. REMOVE FUEL PUMP ASSEMBLY
Pull out the fuel pump assembly.

NOTE: Do not damage the fuel pump filter.
Be careful that the arm of the fuel sender gauge should not bent.







8. REMOVE FUEL SUCTION TUBE SET GASKET
Remove the gasket from the fuel pump assembly.







9. REMOVE FUEL SUCTION SUPPORT NO.2
Using a screwdriver, disconnect the 5 snap claws from the claw holes, and remove the fuel suction support.

NOTE: Do not damage the fuel suction support.







10. REMOVE FUEL PUMP CUSHION RUBBER
Remove the fuel pump cushion rubber.







11. REMOVE FUEL SENDER GAGE ASSY
a. Disconnect the fuel sender gage connector.
b. Using a screwdriver, unlock the fuel sender gage, and slide it remove.







12. REMOVE FUEL SUCTION PLATE SUB-ASSY
a. Disconnect the fuel pump connector.
b. Using a screwdriver, disconnect the 4 snap claws from the claw holes, and pull out the fuel suction plate.

NOTE: Do not damage the fuel suction plate.







13. REMOVE VAPOR PRESSURE SENSOR ASSY
Remove the tube joint clip, and pull out the vapor pressure sensor.







14. REMOVE FUEL PUMP HARNESS
Remove the fuel pump harness from the fuel suction plate.







15. REMOVE FUEL PUMP
Pull out the fuel pump from the fuel filter







16. REMOVE FUEL PUMP FILTER
a. Using a small screwdriver, pry out the clip.
b. Pull out the fuel pump filter from the fuel pump.







17. REMOVE FUEL PRESSURE REGULATOR ASSY
Pull out the fuel pressure regulator from the fuel filter.







18. REMOVE FUEL PRESSURE REGULATOR O-RING
Remove an O-ring from the fuel pressure regulator.







19. INSTALL FUEL PRESSURE REGULATOR O-RING
Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.

20. INSTALL FUEL PUMP FILTER
Install the fuel pump filter with a new clip.







21. INSTALL FUEL PUMP
Apply a light coat of gasoline to an O-ring, and install the fuel pump to the fuel filter.

22. INSTALL VAPOR PRESSURE SENSOR ASSY
Install the vapor pressure sensor with the tube joint clip.

NOTE: Check that there is no scratch or foreign objects on the connecting parts.
Check that the fuel tube joint is inserted fully and securely.
Check that the tube joint clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel tube joint is not pulled off.

23. INSTALL FUEL SUCTION TUBE SET GASKET
Install a new gasket to the fuel pump assembly.

24. INSTALL FUEL PUMP ASSEMBLY
Install the fuel pump assembly to the fuel tank.

NOTE: Do not damage the fuel pump filter.
Be careful that the arm of the fuel sender gauge should not bent.

25. INSTALL FUEL TANK VENT TUBE SET PLATE
Install the fuel tank vent tube set plate with the 5 bolts.

Torque: ...........6.0 N.m (61 kgf.cm, 53 in.lbf)

26. CONNECT FUEL TANK MAIN TUBE SUB-ASSY
Install the fuel tank main tube with the tube joint clip.

NOTE: Check that there is no scratch or foreign objects on the connecting parts.
Check that the fuel tube joint is inserted fully and securely.
Check that the tube joint clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel tube joint is not pulled off.

27. INSTALL FUEL TANK PROTECTOR NO.2
Install the fuel tank protector with the 3 bolts

Torque:...............6.0 N.m (61 kgf.cm, 53 in.lbf)

28. CHECK FUEL LEAK







29. INSTALL REAR FLOOR SERVICE HOLE COVER
Using the butyl tape, install the rear floor service hole cover.

30. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY
Install the rear seat cushion with the 2 bolts.

Torque:........................41 N.m (420 kgf.cm, 30 ft.lbf)