Fuel Pump: Removal

HINT:

See FUEL SYSTEM  .

1. Remove the No. 2 rear floor service hole cover and disconnect the fuel suction tube connector.
   Fig 1: Identifying Fuel Suction Tube Connector

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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 With Pump And Gauge Assembly

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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: Identifying Tube Joint Clips

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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.

   HINT:

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

   Fig 4: Locating Fuel Tank Vent Tube Set Plate Bolts

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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: Identifying Fuel Sender Gage Assembly

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1. Using needle nozzle pliers, remove the E-ring.
   Fig 7: Locating 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: Identifying 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: Identifying 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: Identifying Jet Pump And 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: Locating Connectors And 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: Identifying Fuel Pump

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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 the illustration. 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: Identifying 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: Identifying 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: Identifying Jet Pump

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

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2. Remove the 2 O-rings from the fuel pressure regulator.
   Fig 18: Locating O-Rings

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