Fuel Pump: Service and Repair

Fuel Pump:

REPLACEMENT

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

1. REMOVE LUGGAGE COMPARTMENT BOX

2. REMOVE FLOOR SERVICE HOLE COVER

3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR

4. DISCONNECT VAPOR PRESSURE SENSOR CONNECTOR
a. Remove the 2 bolts and No. 3 fuel tank protector.
b. Disconnect the sensor connector.

5. DISCONNECT FUEL TANK MAIN TUBE AND EMISSION TUBE

CAUTION:
- Disconnect the fuel tube connector (quick type) observing the precaution.
- As there is retained pressure in the fuel line, prevent if from splashing inside the luggage compartment.

a. Remove the tube joint clip and disconnect the main tube.
b. Disconnect the emission tube.

6. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK
a. Remove the 6 bolts and fuel tank vent tube set plate.
b. Remove the fuel pump and sender gauge assembly.

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

c. Remove the gasket from the pump and sender gauge assembly.

7. REMOVE FUEL SUCTION SUPPORT
a. Using a screwdriver, pry out the fuel suction support.

NOTE: Be careful not to damage the suction support.

b. Remove the rubber cushion.

8. REMOVE FUEL SUCTION PLATE

a. Disconnect the fuel sender gauge connector and ground plate.

b. Using 2 screwdrivers, pry out the fuel suction plate.

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

c. Remove the fuel pump harness.

9. REMOVE FUEL PUMP
Pull out the fuel pump.

10. REMOVE FUEL SUCTION FILTER FROM FUEL PUMP
a. Using a small screwdriver, pry out the clip.
b. Pull out the suction filter.

11. REINSTALL FUEL SUCTION FILTER
Install the suction filter with a new clip.

12. REINSTALL FUEL PUMP
Push the fuel pump into fuel filter assembly.

13. REINSTALL FUEL SUCTION PLATE

a. Connect the fuel pump harness.

b. Install the fuel suction plate to the fuel filter assembly.

c. Connect the fuel sender gauge connector and ground plate.

14. REINSTALL FUEL SUCTION SUPPORT
a. Install the rubber cushion.
b. Install the fuel suction support to the fuel filter assembly.

15. REINSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK
a. Install a new gasket to the fuel pump and sender gauge assembly.
b. Insert the fuel pump assembly into the fuel tank.

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

c. Align the positioning mark of the set plate with the bolt hole position A.
d. Install the fuel tank vent tube set plate with the 6 bolts.

Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)

16. RECONNECT FUEL TANK MAIN TUBE AND EMISSION TUBE

a. Connect the main tube to fuel pump assembly with the tube joint clip.
b. Connect the emission tube to the fuel pump assembly.

NOTE:
- Check that the connector is inserted fully and securely.
- Check that the clip of the tube joint is on the collar of the connector.
- After installing the clip of the tube joint, check that the connector is not pulled off.

17. RECONNECT VAPOR PRESSURE SENSOR CONNECTOR
a. Connect the sensor connector.
b. Install the No. 3 fuel tank protector with the 2 bolts.

18. RECONNECT FUEL PUMP & SENDER GAUGE CONNECTOR

19. CHECK FOR FUEL LEAKS

20. REINSTALL FLOOR SERVICE HOLE COVER

21. REINSTALL LUGGAGE COMPARTMENT BOX