Fuel Pump: Service and Repair

Puel Pump:

REPLACEMENT

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

1. REMOVE LH REAR SEAT
2. REMOVE FLOOR SERVICE HOLE COVER
3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
4. DISCONNECT VAPOR PRESSURE SENSOR CONNECTOR




5. DISCONNECT FUEL TANK MAIN TUBE

CAUTION:
- Disconnect the fuel tube connector (quick type) observing the precaution.
- As there Is retained pressure In the fuel line, prevent if from splashing Inside the luggage compartment.
Remove the tube joint clip and disconnect the main tube.

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




a. Remove the 8 bolts and fuel tank vent tube set plate.




b. Lift up the fuel pump and sender gauge assembly, and disconnect the fuel sub suction hose from the fuel return jet tube and remove the fuel pump, sender gauge assembly and gasket.

NOTE:
- Do not damage the fuel suction filter.
- Be careful that the arm of the sender gauge should not be bent.

c. Remove the gasket from the suction plate.

7. REMOVE FUEL SUCTION SUPPORT




a. Using a screwdriver, pry out the fuel suction support.

NOTE: Be careful not to damage the suction support.

b. Remove the rubber cushion.

8. REMOVE FUEL SUCTION PLATE




a. Disconnect the fuel sender gauge connector and ground plate.




b. Using 2 screwdrivers, pry out the fuel suction plate.

NOTE: Be careful not to damage the suction support and suction plate.




c. Remove the fuel pump harness.

9. REMOVE FUEL PUMP




Pull out the fuel pump.

10. REMOVE FUEL SUCTION FILTER FROM FUEL PUMP




a. Using a small screwdriver, pry out the clip.
b. Pull out the suction filter.

11. REINSTALL FUEL SUCTION FILTER




Install the suction filter with a new clip.

12. REINSTALL FUEL PUMP




Push into the fuel pump.

13. REINSTALL FUEL SUCTION PLATE




a. Connect the fuel pump harness.




b. Install the fuel suction plate and fuel filter assembly.




c. Connect the fuel sender gauge connector and ground plate.

14. INSTALL FUEL SUCTION SUPPORT




a. Install the rubber cushion.
b. Install the fuel suction support to the fuel filter assembly.

15. REINSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK




a. Install a new gasket to the suction plate.
b. Connect the sub suction hose to the fuel return jet tube.
c. Insert the fuel pump assembly into the fuel tank.

NOTE:
- Do not damage the fuel suction filter.
- Be careful that the arm of the sender gauge should not be bent.




d. Align the positioning mark of the set plate with bolt hole position A.
e. Install the fuel tank vent tube set plate with the 8 bolts.

Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)

16. RECONNECT FUEL TANK MAIN TUBE




Connect the main tube with the tube joint clip.






NOTE:
- Check that the connector is inserted fully and securely.
- Check that the clip of the tube joint is on the collar of the connector.
- After Installing the clip of the tube joint, check that the connector Is not pulled off.

17. RECONNECT VAPOR PRESSURE SENSOR CONNECTOR
18. RECONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
19. CHECK FOR FUEL LEAK
20. REINSTALL FLOOR SERVICE HOLE COVER
21. REINSTALL LH REAR SEAT