Fuel Pump: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE REAR SEAT CUSHION SUPPORT BRACKET
a. Remove the 2 bolts and rear seat cushion support bracket.
5. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear floor service hole cover.
6. DISCONNECT FUEL PUMP CONNECTOR
7. DISCONNECT FUEL PUMP 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 clean as 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 plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and disconnect the connector.
8. REMOVE FUEL TANK VENT TUBE SET PLATE BOLT
a. Remove the 8 bolts.
HINT: Only remove the bolts. The fuel tank vent tube set plate is removed in the next step.
9. DISCONNECT NO. 2 FUEL EVAPORATION TUBE SUB-ASSEMBLY
a. Pinch the No. 2 fuel evaporation tube clip and then pull out the No. 2 fuel evaporation tube.
NOTE:
- Check around the connector for dirt or mud before this operation and clean as 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 plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and disconnect the connector.
b. Remove the fuel tank vent tube set plate.
10. REMOVE FUEL PUMP ASSEMBLY WITH FUEL SENDER GAUGE ASSEMBLY
a. Remove the fuel pump with fuel sender gauge from the fuel tank.
CAUTION:
- Do not damage the fuel pump filter.
- Do not bend the arm of the fuel sender gauge.
11. REMOVE NO. 2 FUEL SUCTION SUPPORT
a. Using a screwdriver with its 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.
12. REMOVE FUEL PUMP CUSHION RUBBER
13. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Disconnect the fuel sender gauge connector.
b. Using a screwdriver with its tip wrapped in tape, unfasten the clamp to release the fuel sender gauge. Slide the fuel sender gauge to remove it from the fuel pump.
14. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
a. Disconnect the fuel pump connector.
b. Using a screwdriver with its 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 pump filter.
15. REMOVE FUEL PUMP HARNESS
a. Disconnect the connector.
b. Using a small screwdriver, pry out the fuel pump harness.
16. REMOVE FUEL PUMP
a. Pull out the fuel pump from the fuel filter.
17. REMOVE FUEL PUMP FILTER
a. Using a small screwdriver, pry out the clip.
b. Pull out the fuel pump filter from the fuel pump.
18. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
a. Pull out the fuel pressure regulator from the fuel filter.
b. Remove the O-ring from the fuel pressure regulator.
INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
a. Apply a light coat of gasoline or grease to a new O-ring, and install it onto the fuel pressure regulator.
b. Push the fuel pressure regulator into the fuel filter.
2. INSTALL FUEL PUMP FILTER
a. Install the fuel pump filter with a new clip.
3. INSTALL FUEL PUMP
a. Install the fuel pump to the fuel filter.
4. CONNECT FUEL PUMP HARNESS
a. Connect the fuel pump harness.
b. Connect the connector.
5. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
a. Attach the 4 snap claws to the claw holes.
b. Connect the fuel pump connector.
6. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Install the sender gauge to the fuel pump.
b. Connect the fuel sender gauge connector.
7. INSTALL FUEL PUMP CUSHION RUBBER
8. INSTALL NO. 2 FUEL SUCTION SUPPORT
a. Attach the 5 snap claws to the claw hoses and install the fuel suction support.
9. INSTALL FUEL PUMP ASSEMBLY WITH FUEL SENDER GAUGE ASSEMBLY
a. Install a new gasket onto the fuel pump with fuel sender gauge.
b. Install the fuel pump with fuel sender gauge onto the fuel tank.
10. CONNECT NO. 2 FUEL EVAPORATION TUBE SUBASSEMBLY
a. Set the fuel tank vent tube set plate on the fuel tank.
b. Push the No. 2 fuel evaporation tube onto the pipe until the No. 2 fuel evaporation tube makes a "click" sound.
NOTE:
- Check the connected part for damage or foreign objects.
- After connecting, check if the No. 2 fuel evaporation tube and pipe are securely connected by pulling in them.
11. INSTALL FUEL TANK VENT TUBE SET PLATE BOLT
a. Align the marks of the fuel tank vent tube set plate and fuel pump with fuel sender gauge.
b. Install the fuel tank vent tube set plate with the 8 bolts.
Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)
12. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY
a. Install the fuel pump tube with the tube joint clip.
NOTE:
- Check that there are no scratches 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.
13. CONNECT FUEL PUMP CONNECTOR
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
15. CHECK FOR FUEL LEAKS
16. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Using new butyl tape, install the rear floor service hole cover.
17. INSTALL REAR SEAT CUSHION SUPPORT BRACKET
a. Install the bracket with the 2 bolts.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
18. INSTALL REAR SEAT CUSHION ASSEMBLY