FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY

Except for European (L.H.D. U.K.) Specs.

Warning

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.

Caution

Do not touch the fuel pump discharge pipe unless it is necessary. If servicing is needed, be careful not to damage the pipe with tools or other objects, or by applying lateral stress. If the pipe is damaged, it may cause fuel leakage or a fuel pump operation malfunction.

Be careful not to damage the pressure regulator or fuel hose. If it is damaged, it may cause fuel leakage.

When any parts are removed, be careful that no foreign materials penetrate the part. Otherwise it may cause a fuel pump unit operation malfunction.

Protect any removed parts using rubber matting to prevent damage. Furthermore, if a part has been dropped, do not reuse it, replace it with a new one.

Do not use any textile products such as cotton work gloves. If used, fabric may get caught in the fuel pump or pressure regulator causing a fuel pump unit operation malfunction.

Do not touch the flange seal side of the set plate. If it is damaged or foreign material adheres, it may cause fuel leakage.

When removing foreign material inside the reserve cup, use fuel for flushing. If foreign material is removed with air, it may penetrate into the jet pump pressure regulator.

Disassembly

1. Disconnect the fuel pump connector.

2. Remove the arm part of the set plate.

3. Cut the four legs located under the pressure regulator holding cover.

4. Remove the holding cover from the pressure regulator.

Caution

Do not pull out the fuel hose located between the pressure regulator and transfer jet pump. Do not forcedly rotate or bend it, or it could damage the sealing of the fuel hose (press fit area), or cause pipe breakage or splitting. In addition, if the fuel hose is buckled and fuel flow distortion occurs, it may cause jet pump performance deterioration.

Note

Inserting the tip of the flathead screwdriver into the position indicated in the figure, rotate the screwdriver to pry up the pressure regulator slightly (Do not remove completely).

5. Remove the pressure regulator from the fuel filter (high-pressure).

Note

After removing the fuel filter (high-pressure) from the reserve cup, remove the transfer jet pump completely.

6. Remove the transfer jet pump from the reserve cup, and position of the way.

Caution

Be careful not to apply excessive pressure to the reserve cup. Applying excessive pressure may cause splitting, chipping, or bending.

7. Remove the fuel pump and fuel filter as a single unit from the reserve cup while pressing the snap fit tab using a flathead screwdriver.

8. Verify that the reserve cup is not split, chipped, or bent.

9. Remove the O-rings from the transfer jet pump and pressure regulator.

Caution

Grasp the spring end on the set plate side and slowly remove it being careful not to stretch the spring. If the spring is stretched beyond its free length, changes in the fuel pump unit installation load may occur and cause damage to the reserve cup.

10. Remove the spring from the set plate.

Dismounted parts

Assembly

Caution

Be careful not to damage the O-ring. If it is damaged, sealing damage might occur causing fuel leakage.

1. Apply clean oil to the new O-rings.

Caution

Do not pull out the fuel hose between the pressure regulator and transfer jet pump. In addition, do not forcibly rotate or bend it, or it may cause damage to the fuel hose sealing or pipe breakage/splitting. If the fuel hose is buckled and fuel flow distortion occurs, it may cause jet pump performance deterioration.

2. Install a new O-ring to the pressure regulator.

3. Install a new O-ring to the transfer jet pump.

4. Set the transfer jet pump to the reserve cup.

5. Verify that the reserve cup is not split, chipped, or bent.

Note

After installing the fuel filter (high-pressure) to the reserve cup, install the transfer jet pump completely.

6. Install the fuel filter (high-pressure) to the reserve cup.

7. Engage the snap fit tab and reserve cup, and verify that they are properly engaged.

8. Install the transfer jet pump to the reserve cup and pressure regulator to the fuel filter (high-pressure) together at the same time.

9. Install the pressure regulator holding cover and verify that the snap fit tab is properly engaged.

Caution

Grasp the spring end on the set plate side and slowly install it without rotating. If it is rotated, the rubber might wear out.

10. Install the spring to the set plate.

Caution

Do not grasp the pipe located on the upper surface of the set plate. The pipe may be damaged causing fuel leakage.

11. Perform the following procedure to install the set plate to the reserve cup.

Caution

Be careful not to break the set plate arm by applying excessive pressure. If it is broken, it may cause a fuel pump unit operation malfunction.

(1) Insert the set plate arm to the reserve cup.

(2) Engage the snap fit tab and set plate arm, and verify that they are properly engaged.

12. Route the wiring harness under the nylon tube.

13. Connect the fuel pump connector.

14. Press the set plate to expand/contract the fuel pump unit, and inspect it for the following:

The fuel pump connector wiring harness is not pinched into the pressure regulator holding cover.

15. Inspect the following and verify that each part is normal.

Missing part

Engagement condition of snap fit areas

Splitting, chipping, bending, and cracking in each part

Wiring harness routing

Connector condition