Fuel Filter: Service and Repair

REMOVAL

CAUTION: Do not smoke or work near an open frame when working the fuel pump.

1. REMOVE REAR SEAT CUSHION
2. REMOVE FLOOR SERVICE HOLE COVER




Remove the 3 cap nuts and service hole cover.

3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
4. DISCONNECT FUEL TANK MAIN TUBE (FUEL TUBE CONNECTOR) FROM FUEL SECTION PLATE

CAUTION:
- Perform disconnecting operation of the fuel tube connector (quick type) after observing precaution.
- As there is retained pressure in the fuel line, prevent it from splashing inside the vehicle compartment.




a. Remove the tube joint clip.
b. Pull out the fuel main tube.
c. Plug the port of the fuel suction plate with a clean rubber cap.

5. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK




a. Remove the 8 bolts and fuel tank vent tube set plate.




b. Lift up the fuel pump and sender gauge assembly, and disconnect the fuel sub-suction hose from the fuel return jet tube and remove the fuel pump, sender gauge assembly and gasket.

6. REMOVE NO.2 FUEL SUCTION SUPPORT
7. REMOVE FUEL PRESSURE REGULATOR AND FUEL RETURN JET TUBE ASSEMBLY
8. REMOVE FUEL FILTER ASSEMBLY AND FUEL PUMP ASSEMBLY WITH FILTER




a. Using 2 screwdrivers, disconnect the 4 snap claws from the claw holes and remove the fuel filter assembly.

NOTE: Be careful not to damage the filter assembly and suction plate.

b. Disconnect the fuel pump connector.
c. Remove the O-ring from the fuel port of the fuel suction plate.
d. Pull out the fuel pump assembly with filter.

9. REMOVE FUEL SENDER GAUGE ASSEMBLY
Disconnect the connector and slide the fuel sender gauge assembly out of the fuel suction plate.

INSTALLATION

1. INSTALL FUEL SENDER GAGE ASSEMBLY
Slide the fuel sender gage assembly into the fuel suction plate, and connect the connector.

2. INSTALL FUEL FILTER ASSEMBLY AND FUEL PUMP ASSEMBLY WITH FILTER
a. Push in the fuel pump assembly with filter.
b. Apply a light coat of gasoline to a new O-ring, and install it to the fuel port of the fuel suction plate.
c. connect the fuel pump connector.




d. Push the fuel filter assembly, and attach the 4 snap claws to the claw holes.

3. INSTALL FUEL PRESSURE REGULATOR AND FUEL RETURN JET TUBE ASSEMBLY
4. INSTALL NO.2 FUEL SUCTION SUPPORT




5. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK
a. Install a new gasket to the fuel suction plate.
b. Connect the fuel sub-suction hose to the fuel return jet tube.
c. Attach the fuel pump and sender gauge assembly to the fuel tank.




d. Install the fuel tank vent tube set plate with the 8 bolts.

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

6. CONNECT FUEL TANK MAIN TUBE (FUEL TUBE CONNECTOR) TO FUEL SUCTION PLATE




a. Attach the fuel tube connector to the port of the fuel suction plate.
b. Install the tube joint clip.

7. CONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
8. CHECK FOR FUEL LEAKS




9. INSTALL FLOOR SERVICE HOLE COVER
Install the service hole cover with the 3 cap nuts.

10. INSTALL REAR SEAT CUSHION