Fuel Pump: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE NO. 3 ROOM PARTITION PAD
5. REMOVE REAR NO. 2 FLOOR SERVICE HOLE COVER
6. REMOVE FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY
DISASSEMBLY
1. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Disconnect the fuel sender gauge connector.
b. Press down on the sender gauge claw labeled A.
Then slide the sender gauge upward.
2. REMOVE SUB TANK SUB-ASSEMBLY
a. Using a screwdriver, detach the 4 claws from the claw holes and remove the sub-tank.
HINT: Tape the screwdriver tip before use.
3. REMOVE FUEL PUMP ASSEMBLY
a. Disconnect the fuel pump connector.
b. Detach the 2 claws from the claw holes and remove the fuel pump.
c. Remove the fuel pump filter seal from the fuel pump.
d. Remove the fuel pump spacer from the fuel pump.
4. REMOVE FUEL RELIEF VALVE ASSEMBLY
a. Disconnect the fuel pump connector from the fuel filter.
b. Using a screwdriver, detach the claw and remove the relief valve.
5. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
a. Remove the clip and fuel pressure regulator from the relief valve.
b. Remove the 2 O-rings from the fuel pressure regulator.
REASSEMBLY
1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
a. Apply a light coat of gasoline to 2 new O-rings, and install it to the fuel pressure regulator.
b. Install the fuel pressure regulator to the fuel relief valve.
c. Install the clip to the relief valve.
2. INSTALL FUEL RELIEF VALVE ASSEMBLY
a. Apply a light coat of gasoline to a new O-ring, and install the fuel relief valve to the fuel filter.
3. INSTALL FUEL PUMP ASSEMBLY
a. Install the fuel pump spacer to the fuel pump.
b. Apply a light coat of gasoline to a new seal, and install it to the fuel pump.
c. Install the fuel pump to the fuel filter.
d. Connect the fuel pump connector.
4. INSTALL FUEL SUB-TANK ASSEMBLY
a. Apply a light coat of gasoline to a new O-ring, and install the O-ring and fuel sub-tank to the fuel filter.
5. 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.
INSTALLATION
1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY
a. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
b. Connect the fuel tube connector, and set the fuel suction with pump & gauge.
NOTE:
- Be careful not to bend the arm of the fuel sender gauge.
- When connecting the fuel tube connector, do not forcibly pull the tube.
c. Align the protrusion of the fuel suction tube and the cutout of the fuel tank.
d. While holding the fuel suction tube by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Install the fuel pump retainer to the fuel tank.
e. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
SST 09808-14020
HINT: Fit the tips of SST on the ribs of the retainer.
NOTE: Use SST. Do not use any other tools such as a screwdriver.
f. Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that the starting mark on the retainer is within the indicated range in the illustration.
g. Connect the fuel main tube and pump tube.
1. Push the fuel tube joint into the plug of the fuel suction plate, then install the 2 tube joint clips.
h. Connect the fuel suction tube connector.
NOTE:
- Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work.
- Check that the fuel tube joint is securely inserted.
- Check that the tube joint clip is on the collar of the fuel tube joint.
- After installing the tube joint clip, check that the fuel tube cannot be pulled out.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
3. CHECK FOR FUEL LEAKS
4. INSTALL REAR NO. 2 SERVICE HOLE COVER
5. INSTALL NO. 3 ROOM PARTITION PAD
6. INSTALL REAR SEAT CUSHION ASSEMBLY
7. PERFORM INITIALIZATION
a. Perform initialization
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.