Fuel Pump: Service and Repair

Fuel Pump Assembly Removal and Installation

WARNING: Refer to the PRECAUTIONS at the beginning of Precautions on Fuel System Service.

Removal
1) Remove fuel tank from vehicle.





2) Disconnect fuel cut valve hose (1), fuel feed line (2) and fuel return pipe (3) from fuel pump assembly.
When disconnecting joint of fuel feed pipe (2) and fuel return pipe (3) from fuel pump, unlock joint by inserting special tool between pipe and joint lock first.
Special Tool
(A): 09919-47020





3) Remove fuel pump assembly (1) from fuel tank (2).

Installation





1) Clean mating surfaces of fuel pump assembly (1) and fuel tank.
2) Put plate (2) on fuel pump assembly (1) by matching the protrusion of fuel pump assembly (3) to plate hole (4) as shown.





3) Install new gasket (2) and fuel pump assembly (1) with plate (3) to fuel tank.
Tightening torque
Fuel pump assembly bolts (a): 10 Nm (1.0 kgf-cm, 7.5 ft. lbs.)





4) Connect fuel cut valve hose (1), fuel return pipe (2) (pipe joint) and fuel feed line (3) (pipe joint) to fuel pump assembly.

CAUTION: When connecting joint, clean outside surface of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.

5) Install fuel tank to vehicle.

Fuel Pump Assembly Disassembly and Assembly
Disassemble and reassemble fuel pump assembly, noting the following.





CAUTION:
^ While removing fuel level gauge, do not contact resistor plate (1) or deform arm (2). It may cause fuel level gauge to fail.
^ 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.

^ When removing fuel level sensor (3), press snap-fit part (4) and slide it in the arrow direction as shown in figure.
^ When installing fuel level sensor to housing, fit fuel level sensor securely.