Fuel Pump: Service and Repair

Fuel Tank (Part 1):

Fuel Tank (Part 2):

Fuel Pump

A: REMOVAL

WARNING: Place "NO OPEN FLAMES" signs near the working area.

CAUTION:
- Be careful not to spill fuel.
- Prior to start work, be sure to set the fuel volume to three-forth full of the fuel tank. If the fuel is more than three-forth full of the fuel tank, be careful because the fuel may spill out.

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

1. Set the vehicle on a lift.
2. Release the fuel pressure.




3. Disconnect the ground cable from the battery.
4. Open the fuel filler flap lid, and remove the fuel filler cap.
5. Lift up the vehicle.
6. Drain fuel.
7. Remove the rear seat.




8. Remove the service hole cover.




9. Disconnect the connector from fuel pump.
10. Disconnect the quick connector, and then disconnect the fuel delivery hose and jet pump hose.




11. Remove the nuts which install fuel pump assembly onto fuel tank.
12. Remove the fuel pump assembly from the fuel tank.

B: INSTALLATION
Install in the reverse order of removal.

NOTE:
- Use a new gasket.
- Make sure the sealing portion is free from fuel or foreign matter before installation.
- When assembling, point the protrusion of the gasket (A) towards the front of the vehicle.
- Insert the protrusion (B) of the gasket into the upper plate. (3 locations)
- Align the protrusion (C) of the fuel pump assembly to the cut out in the upper plate.
- Tighten the nuts to the specified torque in the order as shown in the figure.






Tightening torque: 4.4 N.m (0.45 kgf-m, 3.2 ft-lb)