Fuel Pump
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE ROOM NO. 3 PARTITION PAD
a. Remove the clip and room partition pad.
5. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the fuel pump connector.
6. REMOVE FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY
a. Disconnect the fuel pump tube.
1. Remove the tube joint clip and fuel tube.
NOTE:
- Remove any dirt and foreign matter on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
b. Loosen the fuel pump gauge retainer.
NOTE: Use SST. Do not use any other tools such as a screwdriver.
1. 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.
2. Using SST, loosen the fuel pump gauge retainer.
c. While holding SST with one hand, remove the fuel pump gauge retainer.
d. Disconnect the fuel return vent tube.
e. Remove the fuel suction with pump and gauge assembly from the fuel tank.
NOTE: Make sure that the sender gauge arm does not bend.
f. Remove the gasket.
7. REMOVE FUEL SENDER GAGE ASSEMBLY
a. Disconnect the fuel sender gauge connector.
b. Press down on the sender gauge claw labeled A. Then slide the sender gauge upward.
8. REMOVE NO. 1 FUEL SUB-TANK
a. Using needle-nose pliers, remove the E-ring.
b. Using a screwdriver with the tip taped, detach the claw of the jet pump nozzle.
c. Using a screwdriver with the tip taped, detach the 3 claws and remove the sub-tank.
d. Using a clip remover with the tip taped, remove the jet pump.
NOTE: The O-ring is installed firmly between the jet pump and sub-tank. Therefore, the jet pump and sub-tank should be removed carefully using a clip remover.
9. REMOVE FUEL PUMP ASSEMBLY
a. Disconnect the 2 connectors and terminal, and remove the fuel pump wire.
b. Using a screwdriver with the tip taped, detach the 2 claws from the claw holes and remove the fuel pump.
c. Remove the fuel pump seal from the fuel pump.
HINT: If the fuel pump seal still remains in the fuel filter, remove it using a wire tip (Dia. 1 mm (0.04 in.)) that is formed as shown in the illustration. Be careful not to damage the seal surface.
d. Remove the fuel pump spacer from the fuel pump.
10. REMOVE FLANGE ASSEMBLY
a. Using a screwdriver with the tip taped, detach the 2 claws and remove the flange and O-ring.
11. REMOVE FUEL RELIEF VALVE ASSEMBLY
a. Using a screwdriver with the tip taped, detach the claw and remove the relief valve.
12. REMOVE FUEL JET PUMP
a. Using a screwdriver with the tip taped, detach the 2 claws and remove the jet pump and O-ring.
13. 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.
INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
a. Apply a light coat of gasoline to 2 new O-rings, and install them 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 JET PUMP
a. Apply a light coat of gasoline to a new O-ring, and install a new O-ring and the jet pump to the fuel relief valve.
3. INSTALL FUEL RELIEF VALVE ASSEMBLY
a. Apply a light coat of gasoline to a new O-ring, and install a new O-ring and the fuel relief valve to the fuel filter.
4. INSTALL FLANGE ASSEMBLY
a. Apply a light coat of gasoline to a new O-ring, and install the O-ring to the flange. Then attach the 2 claws to install the flange to the fuel filter.
5. 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. Attach the 2 claws to install the fuel pump to the fuel filter.
d. Connect the 2 connectors and terminal, and install the fuel pump wire.
6. INSTALL NO. 1 FUEL SUB-TANK
a. Apply gasoline to a new O-ring and install it to the jet pump.
b. Install the jet pump while aligning it to the installation position of the sub-tank.
c. Connect the jet pump nozzle to the sub-tank.
d. Attach the 3 claws to the claw holes and install the sub-tank.
e. Install a new E-ring.
7. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Set the fuel sender gauge to the sub-tank. Then slide the sender gauge downward to install it.
b. Connect the fuel sender gauge connector.
8. 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 return vent tube and set the fuel suction with pump and gauge assembly.
NOTE:
- Be careful not to bend the arm of the fuel sender gauge.
- When connecting the fuel return vent, tube connector do not forcibly pull the tube.
c. Align the protrusion of the flange assembly and the cutout of the fuel tank.
d. While holding the flange assembly by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Then install the fuel pump gauge retainer to the fuel tank.
e. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
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 pump tube.
1. Push the fuel tube joint into the plug of the fuel suction plate, then install the tube joint clip.
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.
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. INSPECT FOR FUEL LEAK
11. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
a. Connect the fuel pump connector.
b. Install the service hole cover with new butyl tape.
12. INSTALL ROOM NO. 3 PARTITION PAD
a. Install the partition pad with the clip.
13. INSTALL REAR SEAT CUSHION ASSEMBLY
14. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.