Fuel Pump: Service and Repair

Fuel Pump Assy:

REPLACEMENT

1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE REAR SEAT CUSHION ASSEMBLY

3. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear floor service hole cover.
b. Disconnect the vapor pressure sensor connector.
c. Disconnect the fuel pump connector.

4. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY

a. Remove the tube joint clip, and pull out the fuel pump tube.

NOTE:
- Before this operation, check the connector for dirt, mud or other contamination.
- Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
- Do not use any tools in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and the connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe.

5. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and the set plate.

6. REMOVE FUEL SUCTION TUBE ASSEMBLY W/ PUMP & GAGE
a. Remove the fuel suction tube from the fuel tank.

NOTE:
- Do not damage the fuel pump filter.
- Do not bend the arm of the fuel sender gage.

b. Remove the gasket from the fuel suction tube.

7. REMOVE VAPOR PRESSURE SENSOR ASSEMBLY
a. Remove the cover.
b. Remove the tube joint clip, and pull out the vapor pressure sensor.

8. REMOVE FUEL SUCTION SUPPORT NO.2
a. Using a screwdriver with its tip wrapped in tape, detach 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

10. REMOVE FUEL SENDER GAGE ASSEMBLY
a. Disconnect the fuel sender gage connector.
b. Using a screwdriver with its tip wrapped in tape, unfasten the clamp to release the fuel sender gage. Slide the fuel sender gage to remove it from the fuel pump.

11. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
a. Disconnect the fuel pump connector.
b. Using a screwdriver with its tip wrapped in tape, detach 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 small 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 small 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 gasoline or grease to a new O-ring, 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
20. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
21. INSTALL FUEL SENDER GAGE ASSEMBLY
22. INSTALL FUEL PUMP CUSHION RUBBER
23. INSTALL FUEL SUCTION SUPPORT NO.2
24. INSTALL VAPOR PRESSURE SENSOR ASSEMBLY
25. INSTALL FUEL SUCTION TUBE ASSEMBLY W/ PUMP & GAGE
a. Install a new gasket to the fuel suction tube.
b. Install the fuel suction tube.

NOTE:
- Do not damage the fuel pump filter.
- Do not bend the arm of the fuel sender gage.

26. 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)

27. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY
a. Install the fuel pump tube with the tube joint clip.

NOTE:
- Check that there are 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 has not been pulled off.

28. CHECK FOR FUEL LEAKS
29. INSTALL REAR FLOOR SERVICE HOLE COVER
30. INSTALL REAR SEAT CUSHION ASSEMBLY