FUEL PUMP REASSEMBLY

PROCEDURE

1. INSTALL FUEL PUMP WITH FILTER ASSEMBLY

   Tech Tips

   Perform "Inspection After Repair" after replacing the fuel pump with filter assembly.

   
   

   • w/ EGR System:

     Click here

   • w/o EGR System:

     Click here

   
   
   1. 

      *1	O-ring
      *2	Fuel Pump Spacer

      Apply a light coat of gasoline to a new O-ring. Then install the O-ring and fuel pump spacer to the fuel pump with filter assembly.

   2. Engage the 5 claws to install the fuel pump with filter assembly to the fuel filter.

      Note

      
      

      • Make sure that the O-ring is not cut or pinched when installing it.

      • Make sure the claws are engaged securely.

      • Do not remove the fuel filter.

2. INSTALL NO. 1 FUEL SUCTION SUPPORT

   
   

   1. Engage the 2 claws to install the No. 1 fuel suction support to the fuel filter.

3. INSTALL FUEL PUMP HARNESS

   
   

   1. Connect the fuel pump harness connector to install fuel pump harness to the fuel pump with filter assembly.

4. INSTALL JET PUMP

   
   

   1. Apply a light coat of gasoline to a new O-ring and install the O-ring to the jet pump.

   2. 

      *1	O-ring
      *a	Notch

      Install the jet pump to the No. 1 fuel sub-tank as shown in the illustration.

   3. Engage the claw to install the fuel tube.

      Note

      
      

      • Make sure that the O-ring is not cut or pinched when installing it.

      • Make sure the claws are engaged securely.

5. INSTALL FUEL FILTER

   
   
   1. 

      *1	No. 1 Fuel Sub-tank
      *a	Tube

      Engage the 2 claws to install the fuel filter and fuel pump with filter assembly to the No. 1 fuel sub-tank.

      Note

      
      

      • Do not apply excessive force to the tube or suction support.

      • Make sure the claws are engaged securely.

6. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY

   
   

   1. Install the spring to the fuel suction plate shaft.

   2. Install the fuel suction plate sub-assembly to the No. 1 fuel sub-tank.

   3. Install a new E-ring to the fuel suction plate shaft.

   4. Connect the fuel pump harness connector to the fuel suction plate sub-assembly.

      Note

      Make sure that the claw of the fuel pump connector is engaged securely.

   5. 

      Connect the fuel pump harness to the clamp as shown in the illustration.

      Note

      
      

      • Engage (A) first and then (B) when connecting the fuel pump harness to the clamp.

      • Do not twist or excessively pull the fuel pump harness.

7. INSTALL FUEL SENDER GAUGE ASSEMBLY

   Click here