Fuel Pump: Service and Repair

FUEL PUMP ASSY

Removal & Installation and Disassembly & Reassembly

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE REAR SEAT ASSY RH
3. REMOVE REAR SEAT ASSY LH
4. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear floor carpet.
b. Remove the rear floor service hole cover.
c. Disconnect the fuel pump connector.

5. SEPARATE FUEL PUMP TUBE SUB-ASSY




a. Check it there is any dirt and/or mud around the connector before this work and clean dirt away.




b. Remove the joint clip, and pull out the fuel pump tube.

NOTE:
- Be careful of dirt and/or mud because the quick connector has an O-ring to seal the pipe and the connector.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- Keep foreign objects off of plug.
- To protect the fuel tube, cover it with a vinyl bag after checking.

6. REMOVE FUEL TANK VENT TUBE SET PLATE




a. Remove the 8 bolts and fuel tank vent tube set plate.

7. REMOVE FUEL SUCTION W/PUMP & GAGE
a. Pull out the fuel suction w/pump & gage from the fuel tank.

NOTE:
- Do not damage the fuel pump filter.
- Be careful that the arm of the sender gauge should not bent.

8. REMOVE FUEL SUCTION SUPPORT NO.2
a. Using a screwdriver, disconnect the snap claws from the claw holes and remove the fuel suction support.

9. REMOVE FUEL PUMP CUSHION RUBBER
10. REMOVE FUEL PRESSURE W/JET PUMP REGULATOR ASSY
11. REMOVE FUEL PUMP ASSY W/FILTER
a. Disconnect the fuel pump connector from the fuel pump.
b. Pull out the fuel filter and the fuel pump assembly.

12. REMOVE FUEL PUMP FILTER
a. Remove the clip.
b. Pull out the suction filter from the fuel pump.

13. REMOVE FUEL SUCTION PLATE SUB-ASSY
a. Using a screwdriver, disconnect the 4 snap claws from the claw holes and remove the fuel suction support.

NOTE: Be careful not to damage the suction support and suction plate.

14. REMOVE FUEL SENDER GAGE ASSY
a. Unlock the sender gage, and move it downward to remove.

15. INSTALL FUEL SENDER GAGE ASSY

a. Lock the sender gage by pushing it upward.

NOTE: By pushing the sender gage downward, confirm that it is certainly locked.

16. INSTALL FUEL PUMP FILTER
a. Install the suction filter with a new clip.

17. INSTALL FUEL PRESSURE W/JET PUMP REGULATOR ASSY
a. Apply gasoline to a new O-ring, and install it to the pressure regulator.
b. Insert the pressure regulator.

18. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Using a new butyl tape set, and install the rear floor service hole cover.

19. INSTALL REAR SEAT ASSY RH
20. INSTALL REAR SEAT ASSY LH
21. INSPECT FOR FUEL LEAKS