Fuel Pump: Service and Repair

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE REAR SEAT CUSHION ASSEMBLY (for Coupe)
3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Convertible)




4. REMOVE REAR FLOOR SERVICE HOLE COVER

a. Remove the rear floor service hole cover.
b. Disconnect the fuel pump connector.




5. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY
a. Remove the tube joint clip, and pull out the fuel pump tube.

NOTE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
- It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Disconnect the quick connector by hand.
- Do not bend, kink or twist the nylon tubes.
- Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off carefully.




6. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and set plate.




7. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
a. Pull out the fuel suction tube from the fuel tank.

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

b. Remove the gasket from the fuel suction tube.




8. REMOVE FUEL NO. 2 SUCTION SUPPORT
a. Using a screwdriver with its tip wrapped with tape, disengage the 5 snap claws from the claw holes, and remove the fuel No. 2 suction support.

NOTE: Do not damage the fuel suction support.




9. REMOVE FUEL PUMP CUSHION RUBBER
a. Remove the fuel pump cushion rubber from the fuel pump.




10. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Disconnect the fuel sender gauge connector (*1).
b. Unlock the fuel sender gauge, and slide it to remove (*2).




11. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
a. Disconnect the fuel pump connector (*1).
b. Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws from the claw holes, and pull out the fuel suction plate.

NOTE: Do not damage the fuel suction support.




12. REMOVE FUEL PUMP HARNESS
a. Disconnect the connector (*1).
b. Using a screwdriver, pry out the fuel pump harness (*2).




13. REMOVE FUEL PUMP
a. Pull out the fuel pump from the fuel filter.




14. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
a. Pull out the fuel pressure regulator from the fuel filter.




b. Remove the O-ring from the fuel pressure regulator.

INSTALLATION




1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
a. Apply a light coat of spindle oil or gasoline to a new O-ring, and install it to the fuel pressure regulator.




b. Push in the fuel pressure regulator to the fuel filter.




2. INSTALL FUEL PUMP
a. Apply a light coat of gasoline or grease to the O-ring of the fuel pump.
b. Push in the fuel pump to the fuel filter.




3. CONNECT FUEL PUMP HARNESS
a. Connect the connector (*1).
b. Install the fuel pump harness (*2).




4. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
a. Connect the fuel pump connector (*1).
b. Install the fuel suction plate.




5. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Slide the fuel sender gauge to engage with the claw (*1).
b. Connect the fuel sender gauge connector (*2).




6. INSTALL FUEL PUMP CUSHION RUBBER
a. Install the fuel pump cushion rubber to the fuel pump.




7. INSTALL FUEL NO. 2 SUCTION SUPPORT
a. Install the fuel No. 2 suction support.




8. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
a. Install a new gasket to the fuel suction tube.
b. Install the fuel suction tube.

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




9. INSTALL FUEL TANK VENT TUBE SET PLATE
a. Align the mark of the set plate with the fuel suction tube.
b. Install the set plate with the 8 bolts.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)




10. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY a. Install the fuel pump tube with the tube joint clip.

NOTE:
- Check that there are no scratches or foreign objects on the connecting part.
- Check that the fuel tube joint is inserted securely.
- Check that the tube joint clip is correctly located on the collar of the fuel tube joint.
- After installing the tube joint clip, check that the fuel tube joint is pulled off.

11. INSPECT FOR FUEL LEAK




12. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel pump connector.
b. Install the rear floor service hole cover with new butyl tape.

13. INSTALL REAR SEAT CUSHION ASSEMBLY (for Coupe)
14. INSTALL REAR SEAT CUSHION ASSEMBLY (for Convertible)