Fuel Pump: Service and Repair

Fuel Pump

REMOVAL

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

CAUTION:
- Be careful not to spill fuel.
- If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill.

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

1. Release the fuel pressure.
2. Drain fuel.
3. Disconnect the ground cable from battery.






4. Remove the rear seat cushion.
5. Remove the service hole cover of fuel pump.






6. Disconnect connectors from the fuel pump, and move aside the service hole cover.






7. Disconnect the quick connector of fuel delivery tube and jet pump tube.

NOTE: Disconnect the quick connector as shown in the figure.










8. Remove the nuts which hold the fuel pump upper plate to the fuel tank.






9. Remove the fuel pump assembly from the fuel tank.

INSTALLATION
Install in the reverse order of removal while being careful of the following.
- Make sure the sealing portion is free from fuel or foreign matter before installation.
- Align protrusion (A) of the gasket to the position shown in the figure.
- Insert the protrusion (B) of gasket to the fuel pump upper plate. (3 places)
- Align the protrusion (C) of fuel pump assembly with the cutout on the fuel pump upper plate.
- Tighten the nuts to the specified torque in the order as shown in the figure.

NOTE: Use a new gasket.

Tightening torque: 4.4 N.m (0.4 kgf-m, 3.2 ft-lb)






CAUTION:
- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
- When connecting the quick connector, make sure to insert the pipe all the way in before locking the slider.
- When it is difficult to lock the slider, check that the pipe is fully inserted.
- Make sure that the quick connector is securely connected.