Fuel Pump: Service and Repair

Fuel Pump:

REMOVAL

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

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE REAR NO. 1 SEAT
a. Remove the 2 seats.

4. REMOVE REAR DOOR SCUFF PLATE
5. REMOVE STEP PLATE
6. REMOVE REAR SEAT LOCK COVER
7. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Take off the front and rear floor carpets.
b. Remove the 2 screws and floor service hole cover.

8. DISCONNECT FUEL MAIN TUBE AND RETURN TUBE

CAUTION:
- Prevent the retained pressure in the fuel line from splashing inside the vehicle compartment.
- When sealing the tube and suction plates with the O-ring of the quick connector, be careful not to damage any contact surfaces or allow foreign matter to contact any surface.
- Be sure to perform the disconnection by hand. Do not use tools.
- Do not bend or turn the nylon tube by force.

a. Before the operation, remove foreign matter or dirt sticking to the tube joint clips.
b. Widen the tip of the clips with your fingers and pull them out for disconnection.

c. Pull out the fuel main tube and the return tube. If the nylon tube and the suction plate stick together, turn the nylon tube with your fingers and pull it out for disconnection.

NOTE: Plug the port and the fuel suction plate with a clean rubber cap.

d. After the disconnection, protect the connector with a plastic bag.

9. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY

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 that the arm of the sender gauge is not bent.

c. Remove the gasket from the fuel suction plate.

10. REMOVE LEAD WIRE
a. Remove the lead wire from the fuel pump.

11. REMOVE FUEL PUMP

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.

d. Using a screwdriver, detach the 4 claws from the claw holes and disconnect the fuel pump and fuel pump filter assembly.

HINT: Tape the screwdriver tip before use.

e. Remove the O-ring from the fuel pump.

12. REMOVE FUEL PUMP FILTER
a. Remove the fuel pump filter from the fuel

INSTALLATION

1. INSTALL FUEL PUMP FILTER
Install the fuel pump filter to the fuel pump.

2. INSTALL FUEL PUMP
a. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pump.
b. Attach the 4 claws to the claw holes and install the fuel pump and fuel pump filter assembly.

c. Install the rubber cushion to the fuel pump.
d. Connect the fuel hose to the outlet port of the fuel pump.
e. Install the fuel pump by pushing the lower side of the fuel pump.

3. INSTALL LEAD WIRE
a. Install the lead wire to the fuel pump.

4. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY
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 tank vent tube set plate with the 8 bolts.

Torque: 3.5 N.m (35 kgf.cm, 31 in.lbf)

5. CONNECT FUEL MAIN TUBE AND RETURN TUBE (FUEL TUBE CONNECTORS)
a. Before installing the tube connectors, check for foreign matter on the connection between the nylon tube and the suction plate.
b. Attach the fuel tube connectors to the ports of the fuel suction plate and insert the clips until you hear a click.

c. After the connection, pull the clips to check that they are installed securely.

6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
7. CHECK FOR FUEL LEAKS
8. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Install the service hole cover with the 2 screws.
b. Install the front and rear floor carpets.

9. INSTALL REAR SEAT LOCK COVER
10. INSTALL STEP PLATE
11. INSTALL REAR DOOR SCUFF PLATE
12. INSTALL REAR NO. 1 SEAT
a. Install the 2 seats.

13. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.