Fuel Pump: Service and Repair

REMOVAL

WARNING: Do not smoke or work near an open flame when working on the fuel pump.

INSTALLATION HINT: Installation is in the reverse order of removal.




1. REMOVE REAR SEAT CUSHION
2. REMOVE FLOOR SERVICE HOLE COVER
- Disconnect the fuel pump connector.
- Remove the 5 screws and service hole cover.

INSTALLATION HINT: Check for fuel leakage.

3. REMOVE FUEL PUMP LEAD WIRE

NOTICE: Do not lift the fuel pump up with the wire harness picking.




4. DISCONNECT FUEL PIPE AND HOSE FROM FUEL PUMP BRACKET

CAUTION: Remove the fuel filter cap to prevent the fuel from flowing out.

- Using SST (SST 09631-22020), disconnect the outlet pipe from the pump bracket.
- Disconnect the return hose from the pump bracket.

Torque: 28 Nm (21 ft lb) for use with SST




5. REMOVE FUEL PUMP BRACKET ASSEMBLY FROM FUEL TANK.
- Remove the 8 bolts.

Torque: 4 Nm (35 in lb)

- Pull out the pump bracket assembly.
- Remove the gasket from the pump bracket.

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

INSTALLATION HINT: Install a new gasket to the pump bracket.




COMPONENTS FOR DISASSEMBLY AND ASSEMBLY

FUEL PUMP DISASSEMBLY

INSTALLATION HINT: Assembly is in the reverse order of disassembly.

1. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
- Remove the fuel pump lead wire.




- Pull off the lower side of the fuel pump from the pump bracket.
- Disconnect the fuel hose from the fuel pump, and remove the fuel pump.
- Remove the rubber cushion from the fuel pump.
2. REMOVE FUEL SENDER GAUGE FROM FUEL PUMP BRACKET
- Disconnect the fuel sender gauge connector.




- Remove the 2 screws and sender gauge.
3. REMOVE FUEL PUMP FILTER FROM FUEL PUMP




- Using a small screwdriver, remove the clip.
- Pull out the pump filter.

INSTALLATION HINT: Install the pump filter with a new clip.

4. REMOVE CONNECTOR




- Remove the 2 screws, connector support, connector and gasket.

INSTALLATION HINT: Install the connector with a new gasket.