Fuel Pump: Service and Repair

WARNING: When replacing fuel line parts, be sure to observe the following:
* Put a "CAUTION: FLAMMABLE" sign in workshop.
* Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
* Be sure to furnish the workshop with a CO2 fire extinguisher.

CAUTION: Before removing fuel line parts, carry out the following procedures:
* Put drained fuel in an explosion-proof container and put lid on securely.
* Release fuel pressure from fuel line.
* Disconnect battery ground cable.
* Always replace O-ring with new ones.
* Do not kink or twist hose and tube when they are installed.
* Do not tighten hose clamps excessively to avoid damaging hoses.
* When installing fuel check valve, be careful of its designated direction.
* After installation, run engine and check for fuel leaks at connections.


FUEL PUMP AND FUEL LEVEL SENSOR UNIT
1. Release fuel pressure from fuel line.

Fuel Pump And Fuel Level Sensor:

2. Remove inspection hole cover located behind the rear seat.
3. Disconnect harness connectors and fuel tubes from upper plate of fuel level sensor unit.
Put mating marks on tubes for correct installation.

4. Remove fuel level sensor retainer and fuel level sensor unit.






5. Disconnect the quick connectors as follows.
1. Put mating marks on tubes and connectors for correct installation.
2. Hold the sides of the connector, push in tabs, and pull out the tube inserted in the retainer.

CAUTION: The tube can be removed when the push in tabs are completely depressed. Do not twist it more than necessary.
Do not use any tools to remove the quick connector.
Keep the connecting portion of the tubes and quick connectors clean.

Fuel Pump Assembly:

6. Remove fuel pump with bracket while lifting the pawl of the fuel pump bracket upward.

Fuel Pump And Fuel Level Sensor:

To install, reverse the removal procedure. Connect the quick connectors as follows:

* Be sure that the connecting portion is clean and smooth.
* Align mating marks.
* Insert tube into the center of the connector until you hear a click.









After connecting quick connectors, make sure the connection is firmly made using the following method.

* Pull on the fuel tube and connector to make sure they are firmly connected.
* Start the engine, increase engine speed and verify that there are no leaks.






Install fuel level sensor unit as shown.