Fuel Pump: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE NO.1 FUEL TANK PROTECTOR SUBASSEMBLY (OFF ROAD PACKAGE)
4. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
5. REMOVE FUEL TANK ASSEMBLY
6. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
7. REMOVE FUEL SUCTION WITH PUMP & GAUGE TUBE ASSEMBLY
8. DRAIN FUEL
DISASSEMBLY
1. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Disconnect the connector.
b. Disengage the claw fitting and remove the sender gauge by sliding it in the direction as shown in the illustration.
2. REMOVE NO. 1 FUEL SUB-TANK
a. Disengage the 5 claw fittings and remove the fuel pump tank.
b. Separate the connector and disengage the clamp.
3. REMOVE FUEL PUMP ASSEMBLY
a. Disengage the clamp, then disconnect the connector.
b. Disengage the 5 claw fittings and separate the fuel pump from the fuel pump case.
c. Disconnect the connector from the fuel pump.
4. REMOVE FUEL PUMP FILTER
a. Remove the fuel filter from the fuel pump.
5. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
a. Remove the fuel pressure regulator and the 2 O-rings.
REASSEMBLY
1. INSTALL FUEL PRESSURE REGULATOR
a. Install the new O-ring into the fuel pump case.
b. Install the new O-ring onto the fuel pressure regulator.
2. INSTALL FUEL PUMP FILTER
3. INSTALL FUEL PUMP ASSEMBLY
4. INSTALL NO.1 FUEL SUB-TANK
5. INSTALL FUEL SENDER GAGE ASSEMBLY
INSTALLATION
1. INSTALL FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY
2. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
3. INSTALL FUEL TANK ASSEMBLY
4. CONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
5. INSTALL NO.1 FUEL TANK PROTECTOR SUBASSEMBLY
6. ADD FUEL
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 N.m (40 kgf.cm, 35 in.lbf)
8. CHECK FOR FUEL LEAKAGE