Fuel Pump: Service and Repair

REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
3. REMOVE REAR SEAT CUSHION ASSEMBLY





4. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Remove the rear floor service hole cover.
(b) Disconnect the vapor pressure sensor connector.
(c) Disconnect the fuel pump connector.

5. REMOVE FUEL SUCTION W/PUMP & GAUGE TUBE ASSEMBLY








(a) Remove the tube joint clip, then pull out the fuel pump tube.

NOTICE:
- Check around the connector for dirt or mud before this operation. Remove the dirt if necessary.
- Be careful of mud because the fuel tube joint has an 0-ring which seals the pipe and connector that can be contaminated.
- Do not use any tools in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release. Pull the connector carefully.





(b) Remove the 8 bolts, then remove the fuel tank vent tube set plate.





(c) Remove the fuel suction tube W/ pump & gauge from the fuel tank.

NOTICE:
- Do not damage the fuel pump filter.
- Do not bend the arm of the fuel sender gauge.

(d) Remove the gasket from the fuel suction tube w/ pump & gauge.





6. REMOVE VAPOR PRESSURE SENSOR ASSEMBLY
(a) Remove the cover.
(b) Remove the tube joint clip, then pull out the vapor pressure sensor.





7. REMOVE FUEL SUCTION SUPPORT NO.2
(a) Using a screwdriver with the tip wrapped in tape, unfasten the 5 claws. Then remove the fuel suction support No.2.

NOTICE: Do not damage the fuel suction support No.2.





8. REMOVE FUEL PUMP CUSHION RUBBER





9. REMOVE FUEL SENDER GAUGE ASSEMBLY
(a) Disconnect the fuel sender gauge connector.
(b) Using a screwdriver with the tip wrapped in tape, unfasten the clamp to release the fuel sender gauge. Then slide the fuel sender gauge to remove it from the fuel pump.





10. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
(a) Disconnect the fuel pump connector.
(b) Using a screwdriver with the tip wrapped in tape, unfasten the 4 claws. Then pull out the fuel suction plate.

NOTICE: Do not damage the fuel suction plate.





11. REMOVE FUEL PUMP HARNESS
(a) Disconnect the connector.
(b) Using a small screwdriver, pry out the fuel pump harness.





12. REMOVE FUEL PUMP
(a) Pull out the fuel pump from the fuel tank fuel filter.





13. REMOVE FUEL PUMP FILTER
(a) Using a small screwdriver, pry out the clip.
(b) Pull out the fuel pump filter from the fuel pump.





14. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
(a) Pull out the fuel pressure regulator from the fuel tank fuel filter.
(b) Remove the O-ring from the fuel pressure regulator.





15. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
(a) Apply a light coat of spindle oil or gasoline to a new O-ring, then install it to the fuel pressure regulator.
(b) Push in the fuel pressure regulator to the fuel tank fuel filter.
16. INSTALL FUEL PUMP FILTER
(a) Install the fuel pump filter with a new clip.





17. INSTALL FUEL PUMP
(a) Apply a light coat of gasoline or spindle oil to the O-ring on the fuel pump.
(b) Push in the fuel pump to the fuel tank fuel filter.
18. INSTALL FUEL PUMP HARNESS
19. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
20. INSTALL FUEL SENDER GAUGE ASSEMBLY
21. INSTALL FUEL PUMP CUSHION RUBBER
22. INSTALL FUEL SUCTION SUPPORT NO.2





23. INSTALL VAPOR PRESSURE SENSOR ASSEMBLY
(a) Install the vapor pressure sensor with the tube joint clip.

NOTICE:
- Check the connected part for scratch or foreign objects.
- Check that the vapor pressure sensor is inserted securely.
- Check that the tube joint clip is on the collar of the vapor pressure sensor.
- After installing the tube joint clip, check that the vapor pressure sensor has not been pulled off.

(b) Install the cover.

24. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY





(a) Install a new gasket to the fuel suction tube W/ pump & gauge.
(b) Install the fuel suction tube w/ pump & gauge to the fuel tank.

NOTICE:
- Do not damage the fuel pump filter.
- Do not bend the arm of the fuel sender gauge.

(c) Align the mark of the fuel tank vent tube set plate with the fuel suction tube W/ pump & gauge.
(d) Install the fuel tank bent tube set plate with the 8 bolts.
Torque: 5.9 N-m (60 kgf-cm, 52 in.-lbf)





(e) Install the fuel pump tube with the tube joint clip.

NOTICE:
- Check the connected part for scratch or foreign objects.
- 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 has not been pulled off.

25. CONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
26. CHECK FOR FUEL LEAKS





27. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the fuel pump connector.
(b) Connect the vapor pressure sensor connector.
(c) Using new butyl tape, install the rear floor service hole cover.
28. INSTALL REAR SEAT CUSHION ASSEMBLY
29. SYSTEM INITIALIZATION