Fuel Pump: Service and Repair
Removal & Installation and Disassembly & Reassembly1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE REAR SEAT CUSHION ASSEMBLY RH
a. Remove the 2 installing bolts of the rear seat cushion.
3. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the 4 screws, then remove the rear floor service hole cover.
b. Disconnect the fuel pump connector.
c. Discharge the fuel system pressure.
1. Connect the battery negative terminal.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
2. Start the engine.
3. Turn the ignition switch to OFF after the engine stops.
HINT: DTC P0171 (system to lean) may be present.
4. Crank the engine again, and check that the engine does not start.
5. Remove the fuel tank cap, and discharge the pressure remaining in the fuel tank completely.
6. Disconnect the battery negative terminal.
4. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY
a. Disconnect the fuel tank main tube.
1. Remove the tube joint clip, then pull the fuel tube joint out of the plug of the fuel suction plate.
NOTE:
- Remove any dirt and foreign objects on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube joint has the O-ring that seals the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag and gum tape after disconnecting the fuel tank main tube.
b. Disconnect the fuel tank vent hose.
1. Pinch the retainer and pull the fuel tank vent connector out of the fuel tank to disconnect the fuel tank vent hose from the fuel suction plate.
NOTE:
- Remove any dirt and foreign objects on the fuel tank vent connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tank vent connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tank vent hose.
- If the fuel tank vent connector and pipe are stuck, push and pull them to release.
c. Using SST, loosen the fuel pump gauge retainer.
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
NOTE: Using SST. Do not use any other tools such as a screwdriver.
HINT: Insert the notch of SST into the rib of the fuel pump gauge retainer.
d. Remove the fuel pump gauge retainer while holding the fuel suction tube by hand.
e. Remove the fuel suction tube from the fuel tank.
NOTE: Make sure that the fuel sender gauge arm does not bend.
f. Remove the gasket from the fuel tank.
5. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Disconnect the fuel sender gauge connector.
b. Separate the claw fitting. Then slide the fuel sender gauge to remove it from the fuel filter.
6. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
a. Remove the E-ring.
b. Separate the claw fitting, then remove the fuel pump filter.
c. Separate the 2 claw fittings, then remove the fuel suction plate and spring.
7. REMOVE FUEL PUMP HARNESS
a. Disconnect the 2 fuel pump harness connectors.
8. REMOVE FUEL SUCTION SUPPORT NO.1
a. Using a screwdriver with its tip wrapped with tape, separate the 2 claws fittings. Then remove the fuel suction support No. 1.
9. REMOVE FUEL PUMP FILTER
a. Using a screwdriver with its tip wrapped with tape, separate the 5 claw fittings. Then remove the fuel pump filter.
NOTE: Do not damage the fuel pump filter and fuel filter.
10. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
a. Pull the fuel pressure regulator out of the fuel filter.
b. Remove the 2 O-rings from the fuel pressure regulator.
11. REMOVE FUEL PUMP
a. Pull the fuel pump out of the fuel filter.
b. Remove the O-ring from the fuel pump.
12. INSTALL FUEL PUMP
a. Apply a light coat of gasoline or spindle oil to a new O-ring, then install it into the fuel pump.
b. Apply a light coat of gasoline or spindle oil to the O-ring of the fuel pump again, then push the fuel pump into the fuel filter.
NOTE: Make sure that the O-ring is not cracked or jammed when installing.
13. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
a. Apply a light coat of gasoline or spindle oil to 2 new O-rings, then install them onto the fuel pressure regulator.
b. Apply a light coat of gasoline or spindle oil to the O-rings of the fuel pressure regulator again, then push the fuel pressure regulator into the fuel filter.
NOTE: Make sure that the O-ring is not cracked or jammed when installing.
14. INSTALL FUEL PUMP FILTER
a. Align the 5 claw positions, then install the fuel pump filter onto the fuel filter.
15. INSTALL FUEL SUCTION SUPPORT NO.1
a. Align the claw positions, then install the fuel suction support No. 1 onto fuel suction plate.
16. INSTALL FUEL PUMP HARNESS
a. Connect the 2 fuel pump harness connectors.
17. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
a. Align the 2 claw positions, then install the fuel suction plate and spring into the fuel suction case.
b. Align the claw position, then install the fuel pump filter onto the fuel suction case.
c. Install a new E-ring.
18. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Slide the fuel sender gauge to fit the claw.
b. Connect the fuel sender gauge connector.
19. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY
a. Install a new gasket onto the fuel tank.
b. Set the fuel suction tube to the fuel tank.
NOTE: Make sure that the fuel sender gauge arm does not bend.
c. Align the protrusion of the fuel suction tube with the notch of the fuel tank.
d. While holding the fuel suction tube by hand, align the marks of a new fuel pump gauge retainer and fuel tank as shown, then install the fuel pump gauge retainer.
e. Using SST and your hand, tighten it by 2 revolution so that the mark of the fuel pump gauge retainer comes within in the range shown in the illustration.
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
NOTE: Use SST. Do not use any other tools such as a screwdriver.
HINT: Insert the notch of SST into the rib of the fuel pump gauge retainer.
f. Connect the fuel tank vent hose.
1. Align the fuel tank vent connector with the pipe,then push in the fuel tank vent connector until the retainer makes a "click" sound to connect the fuel tank vent hose to the fuel suction plate.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tank vent connector and pipe before performing this work.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the quick connector.
g. Connect the fuel tank main tube.
1. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube joint and plug before performing this work.
- Check that the fuel tube joint is securely inserted to the end.
- 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 tank main tube cannot be pulled out.
20. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
21. CHECK FOR FUEL LEAKAGE
NOTE: Check for fuel leakage with the fuel pump connector connected.
22. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel pump connector.
b. Install the rear floor service hole cover with the 4 screws.
23. INSTALL REAR SEAT CUSHION ASSEMBLY RH
a. Install the rear seat cushion with the 2 bolts.
Torque: 41 N.m (420 kgf.cm, 30 ft.lbf)