Fuel Pump: Service and Repair

Fuel Pump Assy:

Fuel Pump Assy:

Removal & Installation and Disassembly & Reassembly

1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE REAR SEAT CUSHION ASSEMBLY
3. REMOVE REAR FLOOR SERVICE HOLE COVER




a. Remove the rear floor service hole cover.
b. Disconnect the fuel pump connector.

4. REMOVE VAPOR PRESSURE SENSOR ASSEMBLY




a. Disconnect the vapor pressure sensor connector.




b. Remove the tube joint clip, and pull out the vapor pressure sensor.

5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY




a. Remove the tube joint clip, and pull out the fuel pump tube.






NOTE:
- Check around the connector for dirt or mud before this operation and remove the dirt if necessary.
- Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.

6. DISCONNECT FUEL EVAPORATION TUBE SUB-ASSEMBLY NO.2




a. Pinch the fuel tube connector clip and then pull out the fuel evaporation tube.






NOTE:
- Check around the connector for dirt or mud before this operation and remove the dirt if necessary.
- Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.

7. REMOVE FUEL TANK VENT TUBE SET PLATE




a. Remove the 8 bolts and fuel tank bent tube set plate.

8. REMOVE FUEL PUMP ASSEMBLY W/ FUEL SENDER GAGE ASSEMBLY




a. Remove the fuel pump w/ fuel sender gage from the fuel tank.

NOTE:
- Do not damage the fuel pump filter.
- Do not bend the arm of the fuel sender gage.

b. Remove the gasket from the fuel pump w/ fuel sender gage.

9. REMOVE FUEL SUCTION SUPPORT NO.2




a. Using a screwdriver with the tip wrapped in tape, detach the 5 snap claws from the claw holes, and remove the fuel suction support.

NOTE: Do not damage the fuel suction support.




10. REMOVE FUEL PUMP CUSHION RUBBER
11. REMOVE FUEL SENDER GAGE ASSEMBLY




a. Disconnect the fuel sender gage connector.
b. Using a screwdriver with the tip wrapped in tape, unfasten the clamp to release the fuel sender gage. Slide the fuel sender gage to remove it from the fuel pump.

12. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY




a. Disconnect the fuel pump connector.
b. Using a screwdriver with the tip wrapped in tape, detach the 4 snap claws from the claw holes, and pull out the fuel suction plate.

NOTE: Do not damage the fuel suction support.

13. REMOVE FUEL PUMP HARNESS




a. Disconnect the connector.
b. Using a small screwdriver, pry out the fuel pump harness.

14. REMOVE FUEL PUMP ASSEMBLY




a. Pull out the fuel pump from the fuel tank fuel filter.

15. REMOVE FUEL PUMP FILTER




a. Using a small screwdriver, pry out the clip.
b. Pull out the fuel pump filter from the fuel pump.

16. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY




a. Pull out the fuel pressure regulator from the fuel tank fuel filter.
b. Remove the O-ring from the fuel pressure regulator.

17. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
a. Apply a light coat of gasoline or grease to a new O-ring, and install it to the fuel pressure regulator.
b. Push in the fuel pressure regulator to the fuel tank fuel filter.

18. INSTALL FUEL PUMP FILTER
a. Install the fuel pump filter with a new clip.

19. INSTALL FUEL PUMP ASSEMBLY W/ FUEL SENDER GAGE ASSEMBLY
a. Install a new gasket to the fuel pump w/ fuel sender gage.
b. Install the fuel pump w/ fuel sender gage to the fuel tank.

20. INSTALL FUEL TANK VENT TUBE SET PLATE




a. Align the mark of the fuel tank vent tube set plate with fuel pump w/ fuel sender gage.
b. Install the fuel tank vent tube set plate with the 8 bolts.

Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)

21. CONNECT FUEL EVAPORATION TUBE SUB-ASSEMBLY NO.2
a. Push in the fuel tube connector to the pipe until the fuel tube connector makes a "click" sound.

NOTE:
- Check the connected part for damage or foreign objects on the connecting part.
- After connecting, check if the fuel tube connector and pipe are securely connected by pulling on them.

22. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY




a. Install the fuel pump tube with the tube joint clip.

NOTE:
- Check that there is no scratch or foreign objects on the connected part.
- Check that the fuel tube joint is inserted securely.
- 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 is not pulled off.

23. INSTALL VAPOR PRESSURE SENSOR ASSEMBLY




a. Install the vapor pressure sensor with the tube joint clip.

NOTE:
- Check that there is no scratch or foreign objects on the connected part.
- Check that the vapor pressure sensor joint is instead securely.
- Check that the tube joint clip is on the collar of the vapor pressure sensor joint.
- After installing the tube joint clip, check that the vapor pressure sensor joint is not been pulled out.

b. Connect the vapor pressure sensor connector.

24. INSTALL REAR FLOOR SERVICE HOLE COVER




a. Using a new butyl tape, install the rear floor service hole cover.

25. CHECK FOR FUEL LEAKS