Fuel Pump: Service and Repair

REMOVAL

WARNING:
- Place "NO FIRE" signs near the working area.
- Be careful not to spill fuel on the floor.

NOTE: Fuel pump assembly consists of fuel pump and fuel level sensor.

1. Release the fuel pressure.
2. Open the fuel filler flap lid and remove the fuel filler cap.

3. Disconnect the battery ground cable.
4. Lift-up the vehicle.

5. Drain the fuel from fuel tank. Set a container under the vehicle and remove the drain plug from fuel tank.
6. Tighten the fuel drain plug.
Tightening Torque: 26 Nm (2.65 kgf-m, 19.2 ft. lbs)

7. Raise the rear seat and turn the floor mat up.

8. Remove the access hole lid.

9. Disconnect the connector from the fuel pump.
10. Disconnect the quick connector and then disconnect the fuel delivery hose (A).

11. Move the clips, and then disconnect the fuel return hose (B) and jet pump hose (C).

12. Remove the nuts which install the fuel pump assembly onto fuel tank.
13. Take off the fuel pump assembly from the fuel tank.

INSTALLATION

Install in the reverse order of removal. Do the following:
1. Always use new gaskets.
2. Ensure the sealing portion is free from fuel or foreign particles before installation.
3. Tighten the nuts in alphabetical sequence shown in figure to specified torque.

Tightening Torque: 4.4 Nm (0.45 kgf-m, 3.3 ft. lbs)

INSPECTION

Connect the lead harness to the connector terminal of fuel pump and apply battery power supply to check whether the pump operates.

WARNING:
- Wipe off the fuel completely.
- Keep battery as far apart from fuel pump as possible.
- Be sure to turn the battery supply ON and OFF on the battery side.
- Do not run fuel pump for a long time under non-load conditions.