Fuel Pump: Service and Repair

FUEL SUPPLY <2.O L DOHC ENGINE> Fuel Tank
Pre-removal Operation
1. Draining of the Fuel
2. Release of Residual Pressure from High Pressure Fuel Hose

Removal Steps
1. Return hose
2. Vapor hose
3. Clamp
4. Fuel gauge unit connector
5. Electrical fuel pump connector
6. High pressure fuel hose
7. Filler hose
8. Vapor hose
9. Self-locking nut
10. Tank band
11. Fuel tank
12. Vapor hose
13. Fuel tank pressure control valve
14. Fuel gauge unit
15. Electrical fuel pump
16. Drain plug
17. Fuel tank filler tube cap
18. Packing
19. Fuel tank filler tube

Caution:
When disconnecting the high pressure fuel hose, cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.

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
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.

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 GAUGE UNIT
Align the two positioning projections of the packing with the holes in the fuel gauge unit.

Caution:
When mounting the fuel gauge unit, incline the float at the end leftward, and insert it into the fuel tank. Since the reserver cap is provided in the fuel tank, the fuel gauge unit will contact the reserver cap if the fuel gauge unit is inclined rightward during insertion.






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 RETURN HOSE AND VAPOR HOSE IMAGE NO. 1 AND 2

When attaching the fuel hose to the pipe, be sure that the hose is attached as shown in the illustration.
Standard value: 25-30 mm (1.0-1.2 in.)






INSTALLATION OF SELF-LOCKING NUT
Tighten the self-locking nuts until the rear end of the tank band contacts the body.






CONNECTION OF VAPOR HOSE IMAGE No. 7 FILLER HOSE
(1) The vapor hose should be connected all the way at the tank, and approximately 40 mm (1.6 in.) at the filler neck.
(2) The end of the filler hose with the shorter straight pipe part should be connected at the tank side.






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.