Fuel Pump: Service and Repair

Fuel Pump Assy (2AZ-FE):

Fuel Pump Assy (2AZ-FE) Part 2:

Removal & Installation and Disassembly & Reassembly
1. REMOVE REAR SEAT CUSHION ASSEMBLY
2. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the service hole cover.
b. Disconnect the fuel pump connector.

3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT




4. SEPARATE FUEL PUMP TUBE SUB-ASSY
a. Check if there is any dirt like mud around the connector before this work and clean dirt away.




b. Remove the joint clip, and pull out the fuel pump tube.

NOTE:
- Be careful of dirt like mud because the quick connector has an O-ring to seal the pipe and the connector.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- Keep off plug from foreign subjects.
- To protect the fuel tube, cover it with a vinyl bag after checking.




5. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and fuel tank vent tube set plate.

6. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
a. Pull out the fuel suction w/pump & gage from the fuel tank.

NOTE:
- Do not damage the fuel pump filter.
- Be careful that the arm of the sender gage should not be

b. Remove the fuel suction tube gasket.


7. REMOVE FUEL SUCTION SUPPORT N0.2
a. Using a screwdriver, disconnect the snap claws from the claw holes and remove the fuel suction support No.2.

8. REMOVE FUEL PUMP CUSHION RUBBER
9. REMOVE FUEL PRESSURE REGULATOR ASSY

10. REMOVE FUEL PUMP ASSY W/FILTER
a. Disconnect the fuel pump connector from the fuel pump.
b. Pull out the fuel filter and the fuel pump assembly.

11. REMOVE FUEL PUMP FILTER
a. Using a screwdriver, remove the fuel pump filter clip and the fuel pump filter.

12. REMOVE FUEL SUCTION PLATE SUB-ASSY
a. Using a screwdriver, disconnect the snap claws from the claw holes and remove the fuel suction plate.

13. REMOVE FUEL SENDER GAGE ASSY
a. Unlock the sender gage, and move it downward to remove.

14. REMOVE FUEL PUMP HARNESS
a. Disconnect the connector, and remove the fuel pump harness.

15. INSTALL FUEL SENDER GAGE ASSY
a. Lock the sender gage by pushing it upward.

NOTE: By pushing the sender gage downward, confirm that it is certainly locked.

16. INSTALL FUEL PUMP FILTER
a. Install the fuel pump filter with a new fuel pump titter clip.

17. INSTALL FUEL PRESSURE REGULATOR ASSY
a. Apply gasoline to a new O-ring, and install it to the pressure regulator.
b. Insert the pressure regulator.

18. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
a. Install a new gasket and fuel suction tube w/pump & gage.




19. INSTALL FUEL TANK VENT TUBE SET PLATE
a. Install the fuel tank vent tube set plate with the 8 bolts.

3.5 N.m (36 kgf.cm, 31 in.lbf)




20. INSTALL FUEL PUMP TUBE SUB-ASSY
a. Connect the main tube with the tube joint clip.

NOTE:
- Check that there is no scratch or foreign objects on the connecting part.
- Check that the connector is inserted fully and securely.
- Check that the clip of the tube joint is on the coller of the connector.
- After installing the clip of the tube joint, check that the connector is not pulled off.

21. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Using a new butyl tape set, and install the rear floor service hole cover.

22. INSPECT FUEL LEAK