Fuel Pump: Service and Repair

REMOVAL

CAUTION: Do not smoke or work near an open flame when working on
the fuel pump.

1. REMOVE FUEL TANK

HINT: At the time of installation, check for fuel leaks.

2. DISCONNECT FUEL TUBE




a. Wash away the mud, dust and the like on the fuel suction plate with water.
b. Pull off the tube joint clip from the fuel suction plate.
c. Disconnect the fuel tube from the fuel pump assembly.




d. Affix the tape in order to prevent the port portion from the dust.




e. Prevent the disconnected fuel tube from damaging and mixing foreign objects by covering them with a vinyl bag.

3. REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK




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

Torque: 4.0 N.m (40 kgf.cm, 35 in.lbf)

b. Pull out the fuel pump assembly.

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

c. Remove the gasket from the fuel pump.

DISASSEMBLY

1. REMOVE VAPOR PRESSURE SENSOR
Pull off the joint clip and remove the vapor pressure sensor from the No.1 fuel suction support.

2. REMOVE NO.2 FUEL SUCTION SUPPORT




a. Using a small screwdriver, pry out the suction support.
b. Remove the rubber cushion.

3. REMOVE FUEL PRESSURE REGULATOR




Pull out the fuel pressure regulator from the fuel filter.

4. REMOVE FUEL PUMP FILTER

NOTE: Do not damage the fuel suction support.




a. Using a small screwdriver, pry out the clip.
b. Pull out the pump filter.

5. REMOVE NO.1 FUEL SUCTION SUPPORT




a. Using a small screwdriver, pry out the No.1 fuel suction support.

NOTE: Do not damage the fuel suction support and fuel suction plate.

b. Remove the No.2 fuel filter cushion from fuel filter.

6. REMOVE FUEL FILTER AND FUEL PUMP




a. Remove the fuel filter and pump from the fuel suction plate.




b. Disconnect the fuel pump connector from the fuel pump.

7. REMOVE FUEL PUMP




Pull out the fuel pump from the fuel filter.

REASSEMBLY

1. INSTALL FUEL PUMP




Install the fuel pump to the fuel filter.

2. INSTALL FUEL FILTER AND FUEL PUMP




a. Connect the fuel pump connector to the fuel pump.




b. Install the fuel filter and fuel pump to the fuel suction plate.

3. INSTALL NO.1 FUEL SUCTION SUPPORT




a. Install the No.2 fuel filter cushion to the fuel filter.
b. Install the No.1 fuel suction support to the fuel suction plate.

4. INSTALL FUEL PRESSURE REGULATOR




a. Install the O-ring to the pressure regulator.

HINT: Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator.

b. Connect the pressure regulator from the fuel filter.

5. INSTALL FUEL PUMP FILTER




a. Connect the fuel pump filter to the fuel pump.
b. Install the new clip.
c. Install the rubber cushion.




6. INSTALL NO.2 FUEL SUCTION SUPPORT
Install the No.2 fuel suction support to the No.1 fuel suction support.

7. INSTALL VAPOR PRESSURE SENSOR
Install the vapor pressure sensor and connect the joint clip to the No.1 fuel suction support.

INSTALLATION
Installation is in the reverse order of removal