Fuel Pump: Removal

HINT:

See PRECAUTION  .

1. Remove the No. 2 rear floor service hole cover and disconnect the fuel suction tube connector.

Fig 1: Removing No. 2 Rear Floor Service Hole Cover

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1. Disconnect the connector from the fuel suction with pump and gauge assembly.
2. Disconnect fuel pump tube.
   Fig 2: Disconnecting Connector From Fuel Suction

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   NOTE: Before beginning this procedure, check for foreign matter on the joint clips. Clean if necessary.
   1. Remove the 2 tube joint clips, fuel tank main tube and fuel tank return vent tube.
      Fig 3: Removing Tube Joint Clips, Fuel Tank Main Tube & Fuel Tank Return Vent Tube

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      NOTE:

      • Keep the O-ring free of foreign matter, as it becomes contaminated easily.
      • Do not use any tools in this procedure.
      • Do not forcefully bend or twist the tube.
      • Put the tube in a plastic bag to prevent damage and contamination.
      • If the fuel suction plate and tube are stuck together, pinch the tube and turn it carefully to disconnect it.
      • Be careful not to damage any clips. If a clip is damaged, replace it.
3. Remove the 8 bolts and the fuel tank vent tube set plate.
   Fig 4: Removing Fuel Tank Vent Tube Set Plate

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   HINT:

   While holding the fuel suction tube by hand, remove the fuel tank vent tube set plate.

4. Disconnect the fuel tube.
5. Remove the fuel suction tube from the fuel tank.
   Fig 5: Removing Fuel Suction Tube From Fuel Tank

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   HINT:

   • Make sure that the fuel sender gauge arm does not bend.
   • Do not damage the No. 2 fuel hose.

1. Disconnect the fuel sender gauge connector.
2. Press down on the sender gauge claw labeled A.

   Then slide the sender gauge upward.

Fig 6: Removing Fuel Sender Gauge Assembly

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1. Using needle nozzle pliers, remove the E-ring.
   Fig 7: Removing E-Ring

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2. Using a screwdriver with the tip taped, disengage the claw and remove the jet pump nozzle.
   Fig 8: Removing Jet Pump Nozzle

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3. Using a screwdriver with the tip taped, disengage the 3 claws and remove the No. 1 sub-tank.
   Fig 9: Removing No. 1 Sub-Tank

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4. Using a clip remover with the tip taped, remove the jet pump and No. 1 fuel sub-tank.
   Fig 10: Removing Jet Pump & No. 1 Fuel Sub-Tank

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   NOTE: The O-ring is installed firmly between the jet pump and No. 1 fuel sub-tank. Therefore, the jet pump and No. 1 fuel sub-tank should be removed carefully using a clip remover.

1. Disconnect the 2 connectors and terminal and remove the fuel pump wire.
   Fig 11: Removing Fuel Pump Wire

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2. Using a screwdriver with the tip taped, detach the 2 claws from the claw holes and remove the fuel pump.
   Fig 12: Detaching Claws From Claw Holes

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3. Remove the fuel pump seal from the fuel pump.
   Fig 13: Removing Fuel Pump Seal From Fuel Pump

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   NOTE: If the fuel pump seal still remains in the fuel filter, remove it using a wire tip ( 1 mm) that is formed as shown in Fig 13. Be careful not to damage the sealing surface.

1. Using a screwdriver with the tip taped, disengage the 2 claws and remove the flange assembly.

Fig 14: Removing Flange Assembly

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1. Using a screwdriver with the tip taped, disengage the claw and remove the fuel relief valve assembly.

Fig 15: Removing Fuel Relief Valve Assembly

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1. Using a screwdriver with the tip taped, disengage the 2 claws and remove the jet pump.

Fig 16: Removing Jet Pump

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1. Remove the clip and fuel pressure regulator from the relief valve.
   Fig 17: Removing Fuel Pressure Regulator Assembly

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2. Remove the 2 O-rings from the fuel pressure regulator.

Fig 18: Removing O-Rings From Fuel Pressure Regulator

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