Fuel Pump: Service and Repair

FUEL TANK, PUMP AND GAUGE SENDER UNIT

(Numbers seen within image reflect procedure step numbers)

Remove

1. Disconnect battery negative lead.
2. Depressurize fuel system. See: FUEL INDUCTION AND AIR DELIVERY / FUEL PRESSURE RELEASE / SERVICE AND REPAIR.
3. Remove contents of fuel tank into an approved closed container.
4. Remove fuel filler neck. See: FUEL INDUCTION AND AIR DELIVERY / FUEL TANK / FUEL FILLER HOSE / SERVICE AND REPAIR.
5. Raise vehicle on four post lift.
6. Position container beneath fuel filter to catch spillage.





7. Disconnect feed pipe from fuel filter.
8. Disconnect return pipe, forward of tank.
9. Plug pipes and connections.
10. Support tank with jack.





11. Remove 3 nuts and 2 bolts securing tank cradle to floor pan.





12. Lower tank by 150 mm. Disconnect multiplug from fuel tank unit.
13. Lower tank assembly. Remove from jack.

NOTE: Do not carry out further dismantling if component is removed for access only.

Disassemble

14. Remove tank from cradle.





15. Slacken clip. Remove fill breather pipe from tank unit.
16. Disconnect feed and return pipes from tank unit. Remove each pipe from 2 fuel tank clips.





17. Remove tank unit retaining ring using LRT-19-001. Remove assembly from tank.

WARNING: A QUANTITY OF FUEL WILL BE RETAINED IN THE UNIT, CARE MUST BE TAKEN TO AVOID EXCESSIVE SPILLAGE DURING REMOVAL.

18. Remove tank unit sealing rubber and discard.

Reassemble

19. Fit new sealing rubber.
20. Fit tank unit. Align location marks.
21. Fit retaining ring using LRT-19-001.
22. Connect fuel feed and return pipes to tank unit.

Tighten to 16 Nm (12 ft.lb.)

23. Secure pipes to fuel tank clips.
24. Position fill breather pipe to tank unit. Secure with clip.
25. Position tank in cradle.

Refit

26. Raise fuel tank assembly on jack until multiplug can be connected to tank unit.
27. Raise tank. Align cradle mounting points. Secure with nuts and bolts.
28. Remove plugs from pipes and connections.
29. Using new O-ring, connect fuel spill return pipe.

Tighten to 16 Nm (12 ft.lb.)

30. Using new O-ring, connect fuel feed pipe to filter.

Tighten to 20 Nm (15 ft.lb.)

31. Lower vehicle.
32. Refit fuel filler neck. See: FUEL INDUCTION AND AIR DELIVERY / FUEL TANK / FUEL FILLER HOSE / SERVICE AND REPAIR.
33. Refill fuel tank.
34. Reconnect battery negative lead.