Fuel Pump: Service and Repair

COMPONENTS

REMOVAL

CAUTION: Do not smoke or work near an open frame when working the fuel pump.

1. REMOVE FUEL TANK
2. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
3. DISCONNECT FUEL MAIN TUBE AND RETURN TUBE FROM FUEL PUMP AND SENDER GAUGE ASSEMBLY

4. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK




a. Remove the 8 bolts.
b. Pull out the fuel pump and sender gauge assembly.

NOTE:
- Do not damage the fuel pump filter.
- Be careful not to bend the arm of the sender gauge.

c. Remove the gasket from the fuel section plate.

5. REMOVE LEAD WIRE FROM FUEL PUMP

6. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET




a. Pull out the lower side of the fuel pump from the pump bracket.
b. Disconnect the fuel hose from the fuel pump, and remove the fuel pump.
c. Remove the rubber cushion from the fuel pump.

7. REMOVE FUEL PUMP FILTER FROM FUEL PUMP




a. Using a small screwdriver, remove the clip.
b. Pull out the pump filter.

INSTALLATION

1. INSTALL FUEL PUMP FILTER TO FUEL PUMP
Install the pump filter with a new clip.

2. INSTALL FUEL PUMP TO FUEL PUMP BRACKET
a. Install the rubber cushion to the fuel pump.
b. Connect the fuel hose to the outlet port of the fuel pump.




c. Install the fuel pump by pushing the lower side of the fuel pump.

3. INSTALL LEAD WIRE TO FUEL PUMP

4. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK
a. Install a new gasket to the fuel suction plate.
b. Insert the fuel pump and sender gauge assembly into the fuel tank.




c. Install the fuel pump and sender gauge to the fuel tank with the 8 bolts.

Torque: 3.5 Nm (35 kg.cm, 31 in.lb)

5. CONNECT FUEL MAIN TUBE AND RETURN TUBE TO FUEL PUMP AND SENDER GAUGE ASSEMBLY
6. CONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
7. CHECK FOR FUEL LEAKS
8. INSTALL FUEL TANK