Fuel Filter: Service and Repair

Fuel Pump Assy Part 1:

Fuel Pump Assy Part 2:

Removal & Installation and Disassembly & Reassembly

1. REMOVE REAR SEAT CUSHION PAD

2. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the service hole cover.
b. Disconnect the fuel pump connector.

3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT

4. DISCONNECT FUEL PUMP TUBE SUB-ASSY




a. Check if there is any dirt like mud around the connector before this work and clean dirt away.
b. Remove the joint clip, and pull out the fuel pump tube.

NOTE:
- Be careful of dirt like mud because the quick connector has an O-ring to seal the pipe and the connector.
- Do not use any tool in this work.




- Do not bend or twist the nylon tube by force.
- Keep off plug from foreign objects.
- To protect the fuel tube, cover it with a vinyl bag after checking.




5. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and fuel tank vent tube set plate.

6. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAUGE
a. Pull out the fuel suction tube w/ pump & gauge from the fuel tank.

NOTE:
- Do not damage the fuel pump filter.
- Be careful that the arm of the sender gauge should not bent.

b. Remove the fuel suction tube gasket.

7. REMOVE FUEL SUCTION SUPPORT NO.2
a. Using a screwdriver, disconnect the snap claws from the claw holes and remove the fuel suction support No.2.

8. REMOVE FUEL PUMP CUSHION RUBBER

9. REMOVE FUEL PRESSURE REGULATOR ASSY

10. REMOVE FUEL PUMP ASSY W/ FILTER
a. Disconnect the fuel pump connector from the fuel pump.
b. Pull out the fuel filter and the fuel pump assembly.

11. REMOVE FUEL PUMP FILTER
a. Using a screwdriver, remove the fuel pump filter clip and the fuel pump filter.

12. REMOVE FUEL SUCTION PLATE SUB-ASSY
a. Using a screwdriver, disconnect the snap claws from the claw holes and remove the fuel suction plate.

13. REMOVE FUEL SENDER GAUGE ASSY
a. Unlock the sender gauge, and move it downward to remove.

14. REMOVE FUEL PUMP HARNESS
a. Disconnect the connector, and remove the fuel pump harness.

15. INSTALL FUEL SENDER GAUGE ASSY
a. Lock the sender gauge by pushing it upward.

NOTE: By pushing the sender gauge downward, confirm that it is certainly locked.

16. INSTALL FUEL PUMP FILTER
a. Install the fuel pump filter with a new fuel pump filter clip.

17. INSTALL FUEL PRESSURE REGULATOR ASSY
a. Apply gasoline to a new O-ring, and install it to the pressure regulator.
b. Insert the pressure regulator.

18. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAUGE
a. Install a new gasket and fuel suction tube w/ pump & gauge.




19. INSTALL FUEL TANK VENT TUBE SET PLATE
a. Install the fuel tank vent tube set plate with the 8 bolts.

Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)




20. INSTALL FUEL PUMP TUBE SUB-ASSY
a. Connect the main tube with the tube joint clip.

NOTE:
- Check that there is no scratch or foreign objects on the connecting part.
- Check that the connector is inserted fully and securely.
- Check that the clip of the tube joint is on the collar of the connector.
- After installing the clip of the tube joint, check that the connector is not pulled off.

21. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Using a new butyl tape set, and install the rear floor service hole cover.

22. INSPECT FUEL LEAK