Fuel Pump: Service and Repair
Removal & Installation and Disassembly & Reassembly1. PREVENT GASOLINE FROM SPILLING OUT
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear floor service hole cover.
b. Disconnect the fuel pump connector.
5. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY
a. Remove the tube joint clip, and pull out the fuel pump tube.
NOTE:
- Check that there is no dirt around the fuel tube joint before this work and clean the dirt away.
- Be careful of dirt like mud because the fuel tube joint has O-rings to seal the fuel tube connector and fuel suction plate.
- Do not use any tools in this work.
- Do not bend or twist the nylon tube by force.
- After disconnecting, cover the fuel tube joint with a plastic bag.
- When the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube between fingers, and turn it carefully to release. Disconnect the fuel tank tube.
6. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and set plate.
7. REMOVE FUEL SUCTION TUBE ASSEMBLY W/ PUMP & GAUGE
a. Pull out the fuel suction tube from the fuel tank.
NOTE:
- Do not damage the fuel pump filter.
- Be careful that the arm of the sender gauge should not bend.
b. Remove the gasket from the fuel suction tube.
8. REMOVE FUEL SUCTION SUPPORT NO.2
a. Using a screwdriver with its tip wrapped with tape, disengage the 5 snap claws from the claw holes, and remove the fuel suction support.
NOTE: Do not damage the fuel suction support.
9. REMOVE FUEL PUMP CUSHION RUBBER
a. Remove the fuel pump cushion rubber from the fuel pump.
10. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Disconnect the fuel sender gauge connector.
b. Unlock the fuel sender gauge, and slide it to remove.
11. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
a. Disconnect the fuel pump connector.
b. Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws from the claw holes, and pull out the fuel suction plate.
NOTE: Do not damage the fuel suction support.
12. REMOVE FUEL PUMP HARNESS
a. Disconnect the connector.
b. Using a screwdriver, pry out the fuel pump harness.
13. REMOVE FUEL PUMP
a. Pull out the fuel pump from the fuel tank fuel filter.
14. REMOVE FUEL PUMP FILTER
a. Using a screwdriver, pry out the clip.
b. Pull out the fuel pump filter from the fuel pump.
15. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
a. Pull out the fuel pressure regulator from the fuel tank fuel filter.
b. Remove the O-ring from the fuel pressure regulator.
16. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
a. Apply a light coat of spindle oil or gasoline to a new Oring, and install it to the fuel pressure regulator.
b. Push in the fuel pressure regulator to the fuel tank fuel filter.
17. INSTALL FUEL PUMP FILTER
a. Install the fuel pump filter with a new clip.
18. INSTALL FUEL PUMP
a. Apply a light coat of gasoline or grease to the O-ring of the fuel pump.
b. Push in the fuel pump to the fuel tank fuel filter.
19. INSTALL FUEL PUMP HARNESS
a. Install the fuel pump harness.
b. Connect the connector.
20. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
a. Install the fuel suction plate.
b. Connect the fuel pump connector.
21. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Slide the fuel sender gauge to engage with the claw.
b. Connect the fuel sender gauge connector.
22. INSTALL FUEL PUMP CUSHION RUBBER
a. Install the fuel pump cushion rubber to the fuel pump.
23. INSTALL FUEL SUCTION SUPPORT NO.2
a. Install the fuel suction support No.2.
24. INSTALL FUEL SUCTION TUBE ASSEMBLY W/ PUMP & GAUGE
a. Install a new gasket to the fuel suction tube.
b. Install the fuel suction tube.
NOTE:
- Do not damage the fuel pump filter.
- Be careful that the arm of the sender gauge should not bend.
25. INSTALL FUEL TANK VENT TUBE SET PLATE
a. Align the mark of the set plate with the fuel suction tube.
b. Install the set plate with the 8 bolts.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
26. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY
a. Install the fuel pump tube with the tube joint clip.
NOTE:
- Check that there is no scratches or foreign objects on the connecting part.
- Check that the fuel tube joint is inserted 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 pulled off.
27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
28. CHECK FOR FUEL LEAKS
29. INSTALL REAR FLOOR SERVICE HOLE COVER
30. INSTALL REAR SEAT CUSHION ASSEMBLY
31. PERFORM INITIALIZATION
Some systems need initialization when disconnecting the battery terminal.