Fuel Pressure Regulator: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER
a. Remove the No. 2 rear floor service hole cover and disconnect the fuel suction tube connector.
5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
a. Disconnect the connector from the fuel suction with pump and gauge assembly.
b. Disconnect fuel pump tube.
NOTE: Before beginning this procedure, check for foreign matter on the joint clips. Clean if necessary.
1. Remove the 2 tube joint clips, fuel tank main tube and fuel tank return vent tube.
NOTE
- Keep the O-ring free of foreign matter, as it becomes contaminated easily.
- Do not use any tools in this procedure.
- Do not forcefully bend or twist the tube.
- Put the tube in a plastic bag to prevent damage and contamination.
- If the fuel suction plate and tube are stuck together, pinch the tube and turn it carefully to disconnect it.
- Be careful not to damage any clips. If a clip is damaged, replace it.
c. Remove the 8 bolts and the fuel tank vent tube set plate.
HINT: While holding the fuel suction tube by hand, remove the fuel tank vent tube set plate.
d. Disconnect the fuel tube.
e. Remove the fuel suction tube from the fuel tank.
HINT
- Make sure that the fuel sender gauge arm does not bend.
- Do not damage the No. 2 fuel hose.
6. 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.
7. REMOVE NO.1 FUEL SUB-TANK
a. Using needle nozzle pliers, remove the E-ring.
b. Using a screwdriver with the tip taped, disengage the claw and remove the jet pump nozzle.
c. Using a screwdriver with the tip taped, disengage the 3 claws and remove the No. 1 sub-tank.
d. Using a clip remover with the tip taped, remove the jet pump and No. 1 fuel sub-tank.
NOTE: The O-ring is installed firmly between the jet pump and No. 1 fuel sub-tank. Therefore, the jet pump and No. 1 fuel sub-tank should be removed carefully using a clip remover.
8. REMOVE FUEL PUMP
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.
NOTE: If the fuel pump seal still remains in the fuel filter, remove it using a wire tip (dia 1 mm) that is formed as shown in the illustration. Be careful not to damage the sealing surface.
9. REMOVE FLANGE ASSEMBLY
a. Using a screwdriver with the tip taped, disengage the 2 claws and remove the flange assembly.
10. REMOVE FUEL RELIEF VALVE ASSEMBLY
a. Using a screwdriver with the tip taped, disengage the claw and remove the fuel relief valve assembly.
11. REMOVE JET PUMP
a. Using a screwdriver with the tip taped, disengage the 2 claws and remove the jet pump.
12. 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 the O-ring and jet pump to the fuel relief valve assembly.
3. INSTALL FUEL RELIEF VALVE ASSEMBLY
a. Apply a light coat of gasoline to a new O-ring, and install the O-ring and fuel relief valve assembly 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 and flange assembly to the fuel filter.
5. INSTALL FUEL PUMP
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 2 connectors and terminal.
6. INSTALL NO.1 FUEL SUB-TANK
a. Apply a light coat of gasoline to a new O-ring, and install the O-ring and No. 1 fuel sub-tank to the fuel filter with flange assembly.
b. Connect the jet pump nozzle to the No. 1 fuel sub-tank.
c. Install a new E-ring.
7. INSTALL FUEL SENDER GAGE ASSEMBLY
a. Set the fuel sender gauge to the No. 1 fuel 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 TUBE ASSEMBLY
a. Install a new gasket onto the fuel tank.
b. Connect the fuel hose with the clip.
c. Set the fuel suction tube to the fuel tank.
NOTE:
- Make sure that the fuel sender gauge arm does not bend.
- Do not damage the No. 2 fuel hose.
d. Align the protrusion of the fuel suction tube and the cutout of the fuel tank vent tube set plate.
e. While holding the fuel suction tube by hand, install the fuel tank vent tube to the fuel tank with the 8 bolts.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
f. Connect the fuel tube.
1. Push the fuel tube joint in the plug of the fuel suction plate, then install the 2 tube joint clips.
NOTE:
- Check that there are no scratches or foreign objects on the connecting parts.
- Check that the fuel tube joint is inserted securely.
- Check that the tube joint clips are on the collars of the fuel tube joints.
- After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
- Be careful not to damage any clips. If a clip is damaged, replace it.
g. Connect the fuel suction tube connector.
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK FOR FUEL LEAK
11. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER
a. Install the No. 2 rear floor service hole cover with new butyl tape.
12. INSTALL REAR SEAT CUSHION ASSEMBLY
13. PERFORM INITIALIZATION
a. Perform initialization.
HINT: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.