Fuel Pump: Service and Repair

SERVICE POINTS OF REMOVAL
1. REMOVAL OF SEAT CUSHION






Pulling the lever, raise the front of the seat cushion and remove the seat cushion.






REMOVAL

FUEL PUMP AND FUEL GAUGE UNIT ASSEMBLY ELECTRICAL CONNECTOR IMAGE LOCATION No. 1
1. Disconnect the fuel pump connector.

HOLE COVER IMAGE LOCATION No. 2






FUEL TANK PRESSURE CONTROL VALVE IMAGE LOCATION No. 3
HIGH PRESSURE FUEL HOSE CONNECTION IMAGE LOCATION No. 4
(1) Bleed the residual pressure from inside the fuel pipe line to prevent the fuel from spraying out.
CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the line.
1. Start and run the engine until it stalls, then turn the ignition switch to OFF.
2. Disconnect the battery negative terminal.






(1) Remove the fuel tank pressure control valve.






(2) Check the valve function after a clean rubber hose is installed on it.
(3) Check the valve for crank or leakage.

INSPECTION
- Check the hoses and the pipes for crack or damage.
- Check the fuel tank filler tube cap for malfunction.
- Check the fuel tank for deformation, corrosion or crack.
- Check the fuel tank for dust or foreign material.

NOTE: If the inside of the fuel tank is to be cleaned, use any one of the following:
(1) Kerosene
(2) Trichloroethylene
(3) A neutral emulsion type detergent

SERVICE POINTS OF INSTALLATION
INSTALLATION OF ELECTRICAL FUEL PUMP AND FUEL GAUGE






(1) Align the three positioning projections of the packing with the holes in the fuel pump.






INSTALLATION OF FUEL TANK PRESSURE CONTROL VALVE
Install so the the fuel tank pressure control valve is facing in the direction shown in the figure.






CONNECTION OF HIGH PRESSURE FUEL HOSE TO FUEL PUMP
Temporarily tighten the flare nut by hand, and then tighten it to the specified torque, being careful that the high pressure fuel hose does not become twisted.
Torque Specification: 30-40 Nm, (22-29 ft.lbs)
Caution: When tightening flare nut, be careful not to bend or twist line to prevent damage to fuel pump flow connection.


INSTALLATION OF HOLE COVER






(1) Before installing the hole cover, apply the specified sealant to the rear floor pan. Specified sealant: 3M ATD Part No.8625 or equivalent
(2) After installing the fuel pump and fuel gauge assembly, start the engine and check to ensure that there is no fuel leakage.


SERVICE POINTS OF INSTALLATION






1. INSTALLATION OF SEAT CUSHION
(a) Securely insert the attachment wire of the rear cushion into under the hinge bracket of the seat back.
(b) Pass the rear seat belt buckle.
(c) Securely insert the hook of the seat cushion into the seat support bracket.