Fuel Pump: Service and Repair
Removal & Installation and Disassembly & Reassembly1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE CHARCOAL CANISTER PROTECTOR
3. REMOVE FUEL TANK FILLER HOSE COVER
4. REMOVE FUEL TANK ASSY
5. REMOVE FUEL TANK TO FILLER PIPE HOSE
6. REMOVE FUEL TANK MAIN TUBE SUB ASSY
a. Remove the tube joint clip, and pull out the fuel main tube.
NOTE:
- Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
- Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
b. Unfasten the 4 claws and remove the fuel tank main tube from the fuel tank.
7. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
a. Using SST, loosen the fuel pump gauge retainer.
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
HINT: A rib on the fuel pump gauge retainer can be fitted into a tip of the SST.
b. Remove the fuel pump gauge retainer.
c. Remove the fuel suction tube w/ pump & gage and the gasket from the fuel tank.
NOTE: Be careful not bend the arm of the fuel sender gage.
8. REMOVE VAPOR PRESSURE SENSOR ASSY
a. Remove the cover.
b. Remove the tube joint clip and pull out the vapor pressure sensor.
9. REMOVE FUEL SENDER GAGE ASSY
a. Disconnect the fuel sender gage connector.
b. Unlock the fuel sender gage and slide it to remove.
10. REMOVE FUEL SUCTION PLATE SUB ASSY
a. Using a screwdriver with the tip wrapped in tape, disconnect the 4 snap claws from the claw holes and remove the fuel suction plate.
NOTE: Do not damage the fuel suction plate and the fuel suction support No. 1.
11. REMOVE FUEL PUMP
a. Disconnect the fuel pump connector.
b. Using a small screwdriver with the tip wrapped in tape, disconnect the 2 claws from the claw holes and pull out the fuel pump.
NOTE: Do not damage the fuel pump and the fuel suction plate.
c. Remove the O-ring and the fuel pump spacer from the fuel pump.
12. REMOVE FUEL FILTER ASSY
a. Using a small screwdriver, pry out the clip.
b. Remove the fuel filter from the fuel pump.
13. REMOVE FUEL TUBE JOINT NO.1
a. Remove the connector.
b. Using a screwdriver with the tip wrapped in tape, disconnect the snap claw from the claw hole and pull out the fuel tube joint No. 1.
NOTE: Do not damage the fuel tube joint No. 1 and the fuel suction plate.
14. REMOVE FUEL PUMP HARNESS
a. Remove the fuel pump harness from the fuel tube joint No. 1.
15. REMOVE FUEL PRESSURE REGULATOR ASSY
a. Remove the clip.
b. Pull out the fuel pressure regulator from the fuel suction plate.
c. Remove the 2 O-rings from the fuel pressure regulator.
16. INSTALL FUEL PRESSURE REGULATOR ASSY
a. Apply a light coat of gasoline or spindle oil to the 2 new O-rings, and install it to the fuel pressure regulator.
b. Apply a light coat of gasoline or spindle oil to the 2 O-rings again, and install the fuel pressure regulator to the fuel tube joint No. 1.
c. Install the clip.
17. INSTALL FUEL PUMP HARNESS
18. INSTALL FUEL TUBE JOINT NO.1
a. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel tube joint No. 1.
b. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel fuel tube joint No. 1 to the fuel suction plate.
c. Connect the connector.
19. INSTALL FUEL FILTER ASSY
a. Install the fuel filter with a new clip.
20. INSTALL FUEL PUMP
a. Install the fuel pump spacer to the fuel pump.
b. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel pump.
c. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel pump to the fuel suction plate.
d. Connect the fuel pump connector.
21. INSTALL FUEL SUCTION PLATE SUB ASSY
a. Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel tube joint No. 1.
b. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel suction plate to the fuel suction support No. 1.
22. INSTALL FUEL SENDER GAGE ASSY
23. INSTALL VAPOR PRESSURE SENSOR ASSY
a. Install the vapor pressure sensor with the tube joint clip.
NOTE:
- Check that there is no scratch or foreign objects on the connecting parts.
- Check that the fuel tube joint connector is fully inserted.
- Check that the fuel tube joint clip is on the collar of the fuel tube joint.
- After installing the tube joint clip, check if the fuel tube joint connector is securely connected by pulling it.
24. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
NOTE: Prior to assembly, all the new components must be stabilized at room temperature for minimum 12 hours.
a. Ensure gasket groove is clean and free of foreign particles.
b. Install a new gasket to the fuel tank.
c. Make sure that the gasket sits in the groove.
d. Align the arrow mark of the fuel suction tube w/ pump & gage tube and the tank suction support.
NOTE: Be careful not bend the arm of the fuel sender gage.
e. Align marks on a new fuel pump gauge retainer and the fuel tank.
f. Position the fuel pump gauge retainer on top of the fuel suction w/ pump & gage flange while pushing down the flange on center.
g. While holding the fuel suction tube w/ pump & gage, tighten the pump gauge retainer one complete turn by hand.
NOTE:
- Make sure the fuel suction tube w/ pump & gage anti rotation tab is in the groove during above operation.
- "S" arrow on the fuel tank indicates 0 degrees position.
h. Ensure that no cross threading occurred during installation by checking the gap between the fuel pump gauge retainer and the fuel tank. Confirm that the gap is even. If cross threading occurred, remove the fuel pump gauge retainer and repeat step (g).
i. Using SST, tighten the fuel pump gauge retainer to the specified torque.
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
Torque: 80 to 90 N.m (816 to 918 kgf.cm, 59 to 67 ft.lbf)
NOTE:
- No ratcheting effect allowed when tightening the fuel pump gauge retainer.
- No grease or lubrication allowed on parts during installation.
HINT: A rib on the fuel pump gauge retainer can be fitted into a tip of the SST.
j. Install the fuel pump gauge retainer by one and half turn so that the triangle mark on the fuel pump gauge retainer is between 510° and 570° from the start position.
k. If the triangle mark is not reached 510°, confirm that no cross threading occurred by measuring the gap between the fuel pump gauge retainer and the fuel tank. If cross threading occurred, replace the fuel pump gauge retainer, the gasket and the tank suction tube support.
l. Replace the tank suction tube support.
1. Remove the tank suction tube support from the fuel tank.
2. Install the tank suction tube support to the fuel tank as shown in the illustration.
m. Put a mark on the fuel pump gauge retainer and the fuel tank with paint. This will be the evidence that the fuel pump gauge retainer had been removed.
25. INSTALL FUEL TANK MAIN TUBE SUB ASSY
a. Install in the fuel return tube with the tube joint clip.
NOTE:
- Check that there is no scratch or foreign objects on the connecting part.
- Check that the fuel tube joint is inserted securely.
- Check that the tube joint clip is on the collar of the fuel tube joint.
- After installing the tube joint clip, check that the fuel tube joint has not been pulled off.
26. INSTALL FUEL TANK TO FILLER PIPE HOSE
27. INSTALL FUEL TANK ASSY
28. CHECK FOR FUEL LEAKS
29. INSTALL FUEL TANK FILLER HOSE COVER
30. INSTALL CHARCOAL CANISTER PROTECTOR