Disassembly and Reassembly

DISASSEMBLY

1. REMOVE FUEL SENDER GAUGE ASSEMBLY




a. Disconnect the fuel sender gauge connector from the fuel suction plate.
b. Press down on the sender gauge claw labeled A. Then slide the sender gauge upward.

NOTE: Do not touch the sender plate's resistance plate area or the contact area.

2. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY




a. Disconnect the fuel pump connector from the fuel suction plate.




b. Using needle nose pliers, remove the E-ring.
c. Remove the fuel suction plate and spring from the sub-tank.

3. REMOVE FUEL FILTER




a. Disengage the 2 claws and remove the filter from the sub-tank.

4. REMOVE JET PUMP




a. Using a screwdriver with the tip taped, remove the jet pump from the sub-tank.




b. Remove the O-ring from the jet pump.

5. REMOVE FUEL PUMP ASSEMBLY




a. Disconnect the fuel pump connector from the fuel pump.




b. Disengage the 5 claws on the filter and remove the fuel pump from the fuel filter.
c. Remove the fuel main valve from the fuel filter.
d. Remove the 2 O-rings from the fuel main valve.
e. Remove the O-ring from the fuel filter.
f. Detach the 2 claws of the fuel filter and remove the cap.
g. Remove the fuel pressure regulator from the fuel filter.
h. Remove the 2 O-rings from the pressure regulator.

6. REMOVE BRACKET




a. Using a screwdriver with the tip taped, disengage the claw and remove the bracket.

REASSEMBLY

1. INSTALL BRACKET




a. Install the bracket to the fuel filter.

2. INSTALL FUEL PUMP ASSEMBLY




a. Apply gasoline to a new O-ring. Then install the O-ring and spacer to the fuel pump.




b. Apply a light coat of gasoline to 2 new O-rings, and install them onto the fuel main valve and fuel pressure regulator.




c. Install the fuel main valve and fuel pressure regulator to the fuel filter.
d. Attach the 2 claws of the fuel filter and install the cap.

NOTE:
- Make sure that the fuel main valve and fuel pressure regulator is not installed backwards. If installed backwards, the engine may stall.
- Make sure the O-rings are not cut or pinched during the installation.
- Attach the claws securely.




e. Engage the 5 claws on the fuel filter and install the fuel pump with pump filter.

NOTE:
- Make sure the O-rings are not cut or pinched during the installation.
- Attach the claws securely.




f. Connect the fuel pump connector to the fuel pump.

3. INSTALL JET PUMP




a. Apply gasoline to a new O-ring and install it to the jet pump.




b. Install the jet pump to the sub-tank as shown in the illustration.

4. INSTALL FUEL FILTER ASSEMBLY




a. Install the fuel filter to the sub-tank and attach the 2 claws.

5. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
a. Install the spring to the fuel suction plate shaft.
b. Install the fuel suction plate to the sub-tank.




c. Install a new E-ring.




d. Connect the fuel pump connector to the fuel suction plate.

6. INSTALL FUEL SENDER GAUGE ASSEMBLY




a. Set the fuel sender gauge to the fuel sub-tank. Then slide the sender gauge downward to install it.
b. Connect the fuel sender gauge connector to the fuel suction plate.

NOTE: Do not touch the sender plate's resistance plate area or the contact area.