Fuel Pump: Service and Repair

FUEL PUMP ASSEMBLY (WITH FUEL FILTER, LEVEL GAUGE (SENSOR) AND FUEL CUT VALVE)

REMOVAL
1) Remove fuel tank from vehicle referring to "Fuel Tank Removal".





2) Disconnect electric connector from fuel pump assembly.
3) Disconnect fuel vapor hose and pipes from fuel pump assembly.
For quick joint, disconnect it as follows:
(1) Remove mud, dust and/or foreign material between pipe and joint by blowing compressed air.
(2) Unlock joint lock by inserting special tool between pipe and joint.

Special Tool
(A): 09919-47020

(3) Disconnect joint from pipe.

4) Remove fuel pump assembly from fuel tank.

INSPECTION
Check fuel pump assembly for damage.





Check fuel suction filter for evidence of dirt and contamination. If present, replace or clean and check for presence of dirt in fuel tank.





DISASSEMBLY





1) Disconnect gauge lead wire connector from bracket sub assembly.
2) While pressing snap-fit part, remove fuel level gauge (sender gauge) by sliding it in the arrow direction.

CAUTION: While removing fuel level gauge, do not contact resistor plate or deform arm. It may cause fuel level gauge to fail.





3) Remove bracket located under fuel pump by opening its snap-fit parts with screwdriver.
Then remove cushion.





4) Disconnect fuel pump lead wire connector from bracket sub assembly.
5) Remove fuel pump with lead wire, fuel tube and grommets from bracket sub assembly.
6) Remove lead wire, fuel tube and/or grommets as necessary.





CAUTION: When removing grommet from fuel tube or bracket sub assembly, be very careful not to cause damage to grommet installed section (sealed section in bore). Should it be damaged, replace it with new one, or fuel will leak from that part.

7) Remove housing from bracket sub assembly by opening its snap-fit parts.

REASSEMBLY

NOTE: Use of new parts is recommended for all parts other than fuel pump and fuel level gauge. Also, be sure to use new grommets, or oil leakage may occur.

1) Install lead wire, spacer and new grommet to fuel pump. Check that no foreign object is caught between grommet and fuel pump.
2) Apply engine oil and around grommet and install fuel tube. Check that no foreign object is caught between grommet and fuel tube.





3) Fit cushion and bracket to fuel pump.





4) Install housing to assembly made in Step 3) above. Check that lug of housing fits in window of bracket securely.





5) Install assembly made in Step 4) above to bracket sub assembly. Check that no foreign object is caught between grommet and bracket sub assembly.
Also, check that lug of bracket sub assembly fits in window of housing.
6) Connect lead wire connector and terminal to bracket sub assembly. Check that wire is not twisted.





7) Install fuel level gauge to housing. Fit protrusion of fuel level gauge in groove in housing and slide it up till lug fits in window securely.
8) Connect fuel level gauge connector to bracket sub assembly.

INSTALLATION
1) Clean mating surfaces of fuel pump assembly and fuel tank.





2) Install new gasket, fuel pump assembly and plate to fuel tank. As both fuel pump installation face of fuel tank and plate have cutout section, match them when installing these parts.
3) Tighten fuel pump assembly bolt to specified torque.

Tightening Torque
(a): 10 N.m (1.0 kg.m, 7.5 lb-ft)





4) Connect fuel vapor hose and pipe joints to fuel pump assembly after cleaning pipe inserted to joint.

CAUTION: When connecting joint, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.

5) Connect electric connector to fuel pump assembly.
6) Install fuel tank to vehicle referring to "Fuel Tank Installation".