Fuel Pump: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type)
4. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type)
5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type)
6. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear floor service hole cover.
b. Disconnect the fuel pump connector.
7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY
a. Remove the tube joint clip, and pull out the fuel pump tube.
NOTE:
- Check that there is no dirt around the fuel tube joint before this work and clean any dirt away.
- It is necessary to prevent mud or dirt from entering the fuel tube joint. If mud enters the joint, the O-rings may not seal the fuel tube connector and fuel suction plate properly.
- Do not use any tools in this work.
- Do not bend or twist the nylon tube.
- After disconnecting, cover the fuel tube joint with a plastic bag.
- If the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube between fingers, and turn it carefully to release. Disconnect the fuel tank tube.
8. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and set plate.
9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
a. Pull out the fuel suction tube from the fuel tank.
NOTE:
- Do not damage the fuel pump filter.
- Be careful that the arm of the sender gauge does not bend.
b. Remove the gasket from the fuel suction tube.
DISASSEMBLY
1. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Disconnect the fuel sender gauge connector.
b. Unlock the fuel sender gauge, and slide it to remove.
2. REMOVE FUEL NO. 1 TANK BAND BRACKET
a. Using needle nozzle pliers, remove the E-ring.
b. Disengage the 4 claws of the fuel No. 1 suction support and remove the fuel No. 1 tank band bracket from the fuel suction plate with the fuel filter.
c. Remove the spring from the fuel suction plate.
3. REMOVE FUEL NO. 1 SUCTION SUPPORT
a. Using a screwdriver with the tip taped, disengage the claw and remove the fuel No. 1 suction support.
4. DISCONNECT FUEL PUMP HARNESS
a. Disconnect the fuel pump harness connector from the fuel suction plate.
5. REMOVE FUEL PUMP
a. Using a screwdriver with its tip taped, disengage the 5 claws and pull out the fuel pump from the fuel filter assembly.
NOTE:
- Do not damage the fuel pump filter.
- Do not remove the suction filter.
b. Remove the fuel pump harness connector.
c. Remove the O-ring from the fuel pump.
6. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
a. Using a screwdriver with its tip taped, remove the fuel pressure regulator from the fuel filter.
b. Remove the 2 O-rings from the fuel pressure regulator.
REASSEMBLY
1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
a. Apply a light coat of gasoline to 2 new O-rings, and install them to the fuel pressure regulator.
b. Install the fuel pressure regulator to the fuel filter.
2. INSTALL FUEL PUMP
a. Apply gasoline to a new O-ring and install it to the fuel filter.
b. Connect the fuel pump harness connector.
c. Engage the 5 claws on the fuel filter and install the fuel pump with the pump filter.
3. CONNECT FUEL PUMP HARNESS
a. Connect the fuel pump harness connector from the fuel suction plate.
4. INSTALL FUEL NO. 1 SUCTION SUPPORT
a. Install the fuel No. 1 suction support to the fuel filter.
5. INSTALL FUEL NO.1 TANK BAND BRACKET
a. Install the spring to the fuel suction plate shaft and install them to the fuel No. 1 tank band bracket.
b. Engage the 4 claws of the fuel No. 1 suction support and install the fuel No. 1 tank band bracket to the fuel suction plate with the fuel filter.
c. Install a new E-ring.
6. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Slide the fuel sender gauge to engage the claw.
b. Connect the fuel sender gauge connector.
INSTALLATION
1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
a. Install a new gasket to the fuel suction tube.
b. Install the fuel suction tube.
NOTE:
- Do not damage the fuel pump filter.
- Be careful that the arm of the sender gauge does not bend.
2. INSTALL FUEL TANK VENT TUBE SET PLATE
a. Align the mark of the set plate with the fuel suction tube.
b. Install the set plate with the 8 bolts.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
3. 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 connecting 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 pulled off.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. CHECK FOR FUEL LEAKS
6. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel pump connector.
b. Install the rear floor service hole cover with new butyl tape.
7. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type)
8. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type)
9. INSTALL REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type)