Fuel Pump: Service and Repair

WARNING: Do not smoke or work near an open flame when working on the fuel pump.

FUEL PUMP BRACKET ASSEMBLY REMOVAL

1. DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY.

CAUTION: Work must not be started for at least 90 seconds after the ignition switch is turned to the LOCK position and the NEGATIVE (-) terminal cable is disconnected from the battery.

2. TAKE OUT FLOOR CARPET.
3. REMOVE SPARE WHEEL COVER.
4. REMOVE SPARE WHEEL.
5. REMOVE SERVICE HOLE COVER.

- Remove the 6 nuts and service hole cover.

6. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY.
(a) Disconnect the following connector and hoses:

(1) Fuel pump connector
(2) Fuel outlet hose
(3) Fuel return hose
(4) Fuel breather hose

(b) Remove the retainer clamp.

(c) Using the special service tool spanner (SST# 09808-14010), loosen the retainer.
(d) Remove the retainer, the fuel pump, sender gauge assembly and gasket.

FUEL PUMP REPLACEMENT PROCEDURE

Fuel Pump Bracket Disassembly Procedure
1. REMOVE FUEL SENDER GAUGE FROM FUEL PUMP BRACKET.
(a) Disconnect the connector from the fuel pump bracket.

(b) Remove the 2 screws and sender gauge.

2. REMOVE FUEL PUMP FROM PUMP BRACKET.

(a) Remove the lead wire.

(b) Pull out the lower side of the fuel pump from the pump bracket.
(c) Remove the rubber cushion from the fuel pump.
(d) Disconnect the fuel hose from the fuel pump, and remove the fuel pump.

3. REMOVE FUEL PUMP FILTER FROM FUEL PUMP.

(a) Using a small screwdriver, remove the clip.
(b) Pull out the pump filter.

Fuel Pump Bracket Assembly Procedure
1. INSTALL FUEL PUMP FILTER TO FUEL PUMP.

- Install the pump filter with a new clip.

2. INSTALL FUEL PUMP TO FUEL PUMP BRACKET.
(a) Connect the fuel hose to the outlet port of the fuel pump.
(b) Install the rubber cushion to the fuel pump.

(d) Install the lead wire.

3. INSTALL FUEL SENDER GAUGE TO FUEL PUMP BRACKET.

(a) Install the sender gauge with the 2 screws.
(b) Connect the connector to the fuel pump bracket.

FUEL PUMP BRACKET ASSEMBLY INSTALLATION
1. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY.
(a) Install a new gasket to the fuel tank.
(b) Insert fuel pump and sender gauge assembly into the fuel tank.

(e) Using special service tool (SST# 09808-14010) or equivalent, tighten the retainer until the arrow mark on the retainer is within the lines on the fuel tank.
(f) Check that the arrow marks of the fuel pump bracket and fuel tank are aligned.

(g) Install the retainer clamp.
(h) Connect the following connector and hoses:

(1) Fuel pump connector
(2) Fuel outlet hose (use 2 new gaskets)
Torque: 29 Nm (22 ft.lb)

(3) Fuel return hose
(4) Fuel breather hose

2. REMOVE SERVICE HOLE COVER.

- Remove the 6 nuts and service hole cover.

3. REMOVE SPARE WHEEL
4. REMOVE SPARE WHEEL COVER.
5. TAKE OUT FLOOR CARPET.
6. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY.
7. CHECK FOR FUEL LEAKS.
- Refer to "Check For Fuel Leaks" under System Diagnosis.
- Component Tests and General Diagnostics