Fuel Pump: Service and Repair

FUEL PUMP MODULE REPLACEMENT [AWD]

1. Remove the second seat assembly Second Seat Assembly Removal and Installation) and turn up the floor carpet.





2. Remove the floor inspection lid (LH).





3. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.
4. Release the fuel pressure in the fuel line. [ Service and Repair.]





5. Insert a flat-tip screwdriver [6mm (0.24 inch) wide and 1mm (0.04 inch) thick] into the retainer of the fuel main pipe.





6. Turn the flat-tip screwdriver about 90 degrees to push up the retainer, and disconnect the fuel main pipe from the fuel pump module.





7. Remove the mounting nuts of fuel pump module.





8.
CAUTION:
Pay attention not to damage the fuel level sensor and float of the fuel pump module when removing the fuel pump module from the service hole.

While removing the fuel pump module from the fuel tank, disconnect the suction hose from the fuel pump module to remove the fuel pump module from the service hole.
9. Replace the fuel pump module gasket with a new one.





10.
CAUTION:

- Pay attention not to damage the fuel level sensor and the float of the fuel pump module when installing it to the fuel tank. Pay attention to prevent the float of fuel level sensor from being trapped by the suction hose inside the fuel tank.

- When installing the fuel pump module to the fuel tank, check that the fuel level sensor moving area moves smoothly.

While inserting the fuel pump module into the fuel tank, connect the suction hose to the fuel pump module to install the fuel pump module to the fuel tank.
While inserting the fuel tank pump module into the fuel tank from the service hole, connect the suction hose to the fuel tank pump module to install the fuel tank pump module to the fuel tank.
11. Tighten the fuel pump module mounting nuts to the specified torque.
Tightening torque: 2.5 ± 0.4 Nm (22 ± 4 in-lb)






12. Before the installation, push up the retainer of the fuel main pipe.





13. Connect the connector of fuel main pipe to the fuel pump module securely and push down the retainer of the connector to lock it firmly.
14. After the installation, slightly pull the fuel main pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.





15. Connect the fuel pump module connector and fuel tank differential pressure sensor connector.





16. Install the floor inspection lid (LH).
17. Return the floor carpet to the original condition and install the second seat assembly Second Seat Assembly Removal and Installation).