Fuel Pump: Service and Repair

REMOVAL

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

1. REMOVE REAR SEAT CUSHION
2. REMOVE FLOOR SERVICE HOLE COVER
a. Take out the floor carpet.
b. Remove the service hole cover.




3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR

4. REMOVE PROTECTOR (H/B)
a. Remove the 2 bolts and protector.

5. DISCONNECT FUEL TUBE
a. Wash away the mud, dust and foreign matter 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 tape to the port to prevent dust contamination.




e. Prevent the disconnected fuel tube from damage or foreign matter contamination by covering it with a vinyl bag.




6. REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK
a. Remove the 6 bolts and fuel tank vent tube set plate (H/B).
b. Remove the 8 bolts and fuel tank vent tube set plate (S/D).
c. Pull out the fuel pump assembly.

NOTE:
- Do not damage the fuel pump filter.
- Be careful not to bend the arm of the sensor gauge.

d. Remove the gasket from the pump assembly.

DISASSEMBLY




1. REMOVE NO. 2 FUEL SUCTION SUPPORT
a. Using a small screwdriver, remove the No. 2 fuel suction support.
b. Remove the rubber cushion and fuel pressure regulator.
c. Remove the O-ring from the pressure regulator.




2. REMOVE NO. 1 FUEL SUCTION SUPPORT
a. Disconnect the fuel sender gauge connector.
b. Using a small screwdriver, remove the No. 1 fuel suction support.

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

c. Disconnect the fuel pump harness from the fuel pump.
d. Remove the O-ring from the No. 1 fuel suction support.

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




4. REMOVE FUEL PUMP
a. Remove the fuel pump from the fuel filter.
b. Remove the O-ring from the fuel pump.

REASSEMBLY




1. INSTALL FUEL PUMP
Connect the fuel pump to the fuel filter.

2. 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 to the fuel filter.

3. INSTALL NO. 1 FUEL SUCTION SUPPORT
a. Connect the fuel pump harness to the No. 1 fuel suction support and fuel pump.
b. Install the No. 1 fuel suction support to the fuel filter.
c. Connect the fuel sender gauge connector and earth plate.

4. INSTALL NO. 2 FUEL SUCTION SUPPORT
a. Install the rubber cushion.
b. Install the No. 2 fuel suction support to the No. 1 fuel suction support.

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

INSTALLATION




1. INSTALL FUEL PUMP ASSEMBLY
a. Install the new gasket to the fuel pump assembly.
b. Install the fuel pump assembly to the fuel tank.

NOTE:
- Do not damage the fuel pump filter.
- Be careful not to bend the arm of the sender gauge.

c. Install the 6 bolts and fuel tank vent tube set plate to the fuel tank (H/B).
d. Install the 8 bolts and fuel tank vent tube set plate to the fuel tank (S/D).
Torque: 4.0 Nm (40 kgf.cm, 35 in.lbf)




2. CONNECT FUEL TUBE
a. Clean up around the fuel tube.
b. Connect the fuel tube and emission tube to the fuel pump assembly.
c. Connect the tube joint clip to the fuel suction plate.

3. INSTALL PROTECTOR (H/B)
a. Install the 2 bolts and protector to the fuel tank.

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

4. CONNECT FUEL PUMP AND SENDER GAUGE CONNECTOR AND VAPOR PRESSURE SENSOR CONNECTOR

HINT: Start the engine, check for fuel leakage.

5. INSTALL FLOOR SERVICE HOLE COVER
a. Install the service hole cover.
b. Install the floor carpet.

6. INSTALL REAR SEAT CUSHION