Fuel Pump: Service and Repair
Removal & Installation and Disassembly & Reassembly1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE REAR SEAT CUSHION ASSEMBLY LH
a. Remove the 2 installing bolts of the rear seat cushion.
3. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear service hole cover.
b. Disconnect the fuel pump and vapor pressure sensor connector.
4. DISCHARGE FUEL SYSTEM PRESSURE
a. Start the engine.
b. Turn the ignition switch to OFF after the engine stops.
5. REMOVE FUEL TANK PROTECTOR NO.2
a. Remove the 3 bolts and fuel tank protector.
6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Remove the tube joint clip, and pull the fuel tank main tube out.
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.
- Do not use any tool.
- 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 pump tube.
- When the fuel tube joint and plug are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to disconnect the fuel tank main tube.
7. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 5 bolts and fuel tank vent tube set plate.
8. REMOVE FUEL PUMP ASSEMBLY
a. Pull the fuel pump assembly out.
NOTE:
- Do not damage the fuel pump filter.
- Make sure that the arm of the fuel sender gauge does not bent.
9. REMOVE FUEL SUCTION TUBE SET GASKET
a. Remove the gasket from the fuel pump assembly.
10. REMOVE FUEL SUCTION SUPPORT NO.2
a. 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.
11. REMOVE FUEL PUMP CUSHION RUBBER
a. Remove the fuel pump cushion rubber.
12. REMOVE FUEL SENDER GAGE ASSEMBLY
a. Disconnect the fuel sender gage connector.
b. Using a screwdriver with its tip wrapped in tape, unlock the fuel sender gage, and slide it remove.
13. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
a. Disconnect the fuel pump connector.
b. Using a screwdriver, disconnect the 4 snap claws from the claw holes, and pull the fuel suction plate out.
NOTE: Do not damage the fuel suction plate.
14. REMOVE FUEL PUMP HARNESS
a. Remove the fuel pump harness from the fuel suction plate.
15. REMOVE FUEL PUMP
a. Pull the fuel pump from the fuel filter out.
16. REMOVE FUEL PUMP FILTER
a. Using a small screwdriver, pry out the clip.
b. Pull the fuel pump filter out of the fuel pump.
17. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
a. Pull the fuel pressure regulator out of the fuel filter.
18. REMOVE FUEL PRESSURE REGULATOR O-RING
a. Remove an O-ring from the fuel pressure regulator.
19. INSTALL FUEL PRESSURE REGULATOR O-RING
a. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it onto the fuel pressure regulator.
20. INSTALL FUEL PUMP FILTER
a. Install the fuel pump filter with a new clip.
21. INSTALL FUEL PUMP
a. Apply a light coat of gasoline or spindle oil to an O-ring,and install the fuel pump onto the fuel filter.
22. INSTALL FUEL SUCTION TUBE SET GASKET
a. Install a new gasket onto the fuel pump assembly.
23. INSTALL FUEL PUMP ASSEMBLY
a. Install the fuel pump assembly to the fuel tank.
NOTE:
- Do not damage the fuel pump filter.
- Make sure that the arm of the fuel sender gauge does not bent.
24. INSTALL FUEL TANK VENT TUBE SET PLATE
a. Install the fuel tank vent tube set plate with the 5 bolts.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
25. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Install the fuel tank main tube with the tube joint clip.
NOTE:
- Check that there are no scratches or foreign objects on the connecting parts.
- Check that the fuel tube joint is securely inserted into 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 tube joint cannot be pulled out.
26. INSTALL FUEL TANK PROTECTOR NO.2
a. Install the fuel tank protector with the 3 bolts.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
27. INSTALL REAR SEAT CUSHION ASSEMBLY LH
a. Install the rear seat cushion with the 2 bolts.
Torque: 41 N.m (420 kgf.cm, 30 ft.lbf)
28. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N.m (55 kgf.cm, 48 ft.lbf)
29. CHECK FOR FUEL LEAKAGE
30. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Using the butyl tape, install the rear floor service hole cover.