Fuel Pump: Service and Repair

FUEL PUMP MODULE REPLACEMENT

1. Remove the rear seat cushion assembly.







2. Remove the floor inspection lid (LH).







3. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.
4. Release the fuel pressure in the fuel line.
5. Disconnect the fuel return hose.







6. Insert a flat-tip screwdriver [6mm (0.24 inch) wide and 1mm (0.04 inch) thick] into the retainer of the fuel main pipe.







7. Turn the flat-tip screwdriver about 90 degrees angle to push up the retainer, and disconnect the fuel main pipe from the fuel pump module.







8. Remove the mounting nuts of fuel pump module.

CAUTION: When removing the fuel pump module from the service hole, be careful not to damage the gauge unit and the float of the fuel pump module.







9. Disconnect the fuel tank suction hose while removing the fuel pump module from the service hole, and then remove the fuel pump module from the service hole.
10. Replace the fuel pump module gasket with a new one.

CAUTION:
- When installing the fuel pump module into the fuel tank from the service hole, be careful not to damage the gauge unit and the float of the fuel pump module. In addition, be careful that the float does not catch the fuel tank suction hose in the fuel tank.
- When installing the fuel pump module into the fuel tank from the service hole, check that the moving part of the gauge works smoothly.







11. While inserting the fuel pump module into the fuel tank from the service hole, connect the fuel tank suction hose, and install the fuel pump module to the fuel tank.







12. Before the installation, push up the retainer of the fuel main pipe.







13. Connect the connector of fuel main pipe to the fuel pump module securely and push down the retainer of the connector to lock it firmly.
14. After the installation, slightly pull the fuel main pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.
15. Connect the fuel return hose.







16. Connect the fuel pump module connector and fuel tank differential pressure sensor connector.
17. Install the floor inspection lid (LH).
18. Install the rear seat cushion assembly.