Fuel Pump: Service and Repair

Fuel Pump Assy Part 1:

Fuel Pump Assy Part 2:

REPLACEMENT

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. DRAIN FUEL
4. REMOVE REAR SEAT CUSHION ASSEMBLY

5. REMOVE REAR FLOOR SERVICE HOLE COVER NO.2




a. Remove the 3 cap nuts and service hole cover.

6. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY

NOTE:
- These procedures should be performed with the fuel tank less than 1/4 full.
- Check for dirt and foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools in these procedures.
- Do not forcefully bend or twist the nylon tube.
- Check for dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Put the pipe and connector ends in plastic bags to prevent damage and dirt and foreign matter.
- If the pipe and connector are stuck together, pinch the tube and turn it carefully to free it. Then disconnect the tube.




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

7. REMOVE FUEL TANK VENT TUBE SET PLATE

a. Remove the 8 bolts and set plate.

8. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY




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

NOTE:
- Be careful not to damage the fuel pump filter.
- Be careful not to bend the sender gauge arm.

9. REMOVE FUEL SUCTION SUPPORT NO.2




a. Using 2 screwdrivers, disconnect the 3 snap claws from the claw holes and remove the fuel suction support.

NOTE: Be careful not to damage the suction support and fuel filter.

10. REMOVE FUEL PUMP CUSHION RUBBER
11. REMOVE FUEL PRESSURE W/JET PUMP REGULATOR ASSEMBLY




a. Disconnect the fuel return jet tube from the clamp of the fuel filter.
b. Pull out the fuel pressure regulator from the fuel filter.
c. Remove the O-ring from the fuel pressure regulator.

12. REMOVE FUEL SUCTION PLATE W/SENDER GAUGE




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

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.

13. REMOVE FUEL PUMP ASSEMBLY

a. Pull out the fuel pump with filter.

14. INSTALL FUEL PUMP ASSEMBLY

a. Push in the fuel pump with filter.

15. INSTALL FUEL SUCTION PLATE W/SENDER GAUGE




a. Apply a light coat of gasoline to a new O-ring, and install it to the fuel port of the fuel suction plate.
b. Connect the fuel pump connector.
c. Push the fuel filter, and attach the 4 snap claws to the claw holes.

16. INSTALL FUEL PRESSURE W/JET PUMP REGULATOR ASSEMBLY




a. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
b. Push in the fuel pressure regulator to the fuel filter.
c. Check that the fuel pressure regulator rotates smoothly. If it does not rotate smoothly, the O-ring may be pinched. Remove the fuel pressure regulator and repeat steps b.and c.above.
d. Connect the fuel return jet tube to the clamp of the fuel filter.

17. INSTALL FUEL PUMP CUSHION RUBBER

18. INSTALL FUEL SUCTION SUPPORT NO.2




a. Push the fuel suction support to the fuel filter and attach the 3 snap claws to the claw holes.

19. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY




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 to the fuel tank.

20. INSTALL FUEL TANK VENT TUBE SET PLATE

a. Install the set plate with the 8 bolts.

Torque: 6.0 N.m (61 kgf.cm, 52in.lbf)

21. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY




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

22. INSTALL REAR FLOOR SERVICE HOLE COVER NO.2




a. Install the service hole cover with the 3 cap nuts.

23. INSTALL REAR SEAT CUSHION ASSEMBLY
24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
25. PERFORM INITIALIZATION

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

26. ADD FUEL
27. CHECK FOR FUEL LEAKS