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Fuel Pump Removal/Install

Discussion in 'General Automotive' started by navylife59, Feb 17, 2009.

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  1. navylife59
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    navylife59 Super Moderator Staff Member

    Joined:
    Mar 22, 2006
    Location:
    Emory, Texas or Gretna, LA
    FUEL SYSTEM
    PRECAUTION
    1. BEFORE WORKING ON FUEL SYSTEM
    (a) Do not work near an open flame.
    (b) Keep gasoline away from rubber and leather parts.
    (c) Discharge the fuel pressure before disconnecting the fuel line to prevent gasoline slipping out. Refer to the following procedure.

    Fuel Pump Connections.jpg
    2. DISCHARGE FUEL PRESSURE
    NOTICE:
    DTC P0171 lean fuel trim may be present. Clear DTCs after the repair.
    (a) Remove the rear seat cushion and rear floor service hole cover.
    (b) Disconnect the fuel pump connector.
    (c) Allow the engine to idle until the engine stops.
    (d) Turn the ignition switch OFF.
    (e) Remove the fuel cap to release the fuel tank pressure.
    (f) Connect the fuel pump connector.
    (g) Install the rear floor service hole cover and rear seat cushion.

    Fuel Pump Components.jpg
    Fuel Pump-Filter Assembly.jpg

    REMOVAL
    1. REMOVE REAR SEAT CUSHION ASSEMBLY
    2. REMOVE REAR FLOOR SERVICE HOLE COVER

    (a) Remove the butyl tape, and remove the rear floor service hole cover.
    (b) Disconnect the fuel pump connector.
    (c) Discharge the fuel system pressure.
    (1) Start the engine.
    (2) Turn the ignition switch OFF after the engine
    stops.

    HINT:
    DTC P0171 (system to lean) may be present.

    (3) Crank the engine again and check that the engine does not start.
    (4) Remove the fuel tank cap, and discharge the pressure in the fuel tank completely.
    (d) Disconnect the wire to wire connector.
    3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
    4. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    (a) Disconnect the fuel tank main tube.
    (1) Remove the tube joint clip, and pull the fuel tube joint out of the plug of the fuel suction plate.

    Fuel Tube Joint Clip.jpg
    NOTICE:
    • Remove dirt and foreign objects on the fuel tube joint before performing this
    work.
    • Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube joint has the O-ring that seals the plug.
    • Perform this work by hand. Do not use any tools.
    • Do not forcibly bend, twist or turn the nylon tube.
    • Protect the disconnected part by covering it with a plastic bag and
    protective tape after disconnecting the fuel tank main tube.

    Fuel Plate Access.jpg
    Fuel Pump Assembly Removal.jpg
    (b) Remove the 2 bolts and fuel tank protector plate.
    (c) Remove the 6 bolts and fuel tank vent tube set plate.
    (d) Remove the fuel suction with pump and gauge tube from the fuel tank.

    NOTICE:
    • Do not damage the fuel pump filter.
    • Make sure that the fuel sender gauge arm does not bend.

    (e) Remove the gasket from the fuel suction tube with pump and gauge tube.


    DISASSEMBLY
    1. REMOVE FUEL SENDER GAUGE ASSEMBLY
    (a) Separate the 2 claws fittings, then slide the fuel sender gauge to remove it from the fuel filter.

    Fuel Pump Assembly Disassembly.jpg
    2. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
    (a) Disconnect the fuel pump harness connector.
    (b) Using a screwdriver with its tip wrapped in tape, separate the 4 claws fittings. Then remove the fuel suction plate.

    NOTICE:
    Do not damage the fuel suction plate or fuel tank fuel filter.

    3. REMOVE FUEL PUMP HARNESS
    (a) Remove the 2 pump harness terminals.
    (b) Disconnect the pump harness connector, then remove the fuel pump harness.

    Fuel Pump Assembly Disassembly2.jpg
    4. REMOVE NO. 2 FUEL SUCTION SUPPORT
    (a) Using a screwdriver with its tip wrapped in tape, separate the 5 claws fittings. Then remove the fuel suction support.

    Fuel Pump Assembly Disassembly3.jpg
    NOTICE:
    Do not damage the fuel suction support or fueltank fuel filter.

    5. REMOVE FUEL PUMP CUSHION RUBBER
    (a) Remove the fuel pump cushion rubber from the fuel pump.
    6. REMOVE FUEL PUMP
    (a) Pull the fuel pump out of the fuel filter.

    Fuel Pump Assembly Disassembly4.jpg
    7. REMOVE FUEL PUMP FILTER
    (a) Using a small screwdriver, pry out the clip.
    (b) Remove the fuel pump filter from the fuel pump.

    Fuel Pump Assembly Disassembly5.jpg
    8. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
    (a) Pull the fuel pressure regulator out of the fuel tank fuel filter.
    (b) Remove the O-ring from the fuel pressure regulator.
  2. navylife59
    Offline

    navylife59 Super Moderator Staff Member

    Joined:
    Mar 22, 2006
    Location:
    Emory, Texas or Gretna, LA
    Inspection/Install

    INSPECTION
    1. INSPECT FUEL PUMP
    (a) Check the fuel pump resistance.
    (1) Using an ohmmeter, measure the resistance between terminals 1 and 2.
    Standard resistance:
    0.2 to 3.0 Ω at 20°C (68°F)
    If the result is not as specified, replace the fuel pump.
    (b) Check fuel pump operation.
    (1) Apply battery voltage to terminals 1 and 2. Check that the pump operates.

    Fuel Pump Inspection.jpg
    NOTICE:
    • These tests must be completed within 10 seconds to prevent the coil from burning out.
    • Keep the fuel pump as far away from the battery as possible.
    • Always turn on and off the voltage on the battery side, not the fuel pump side.
    If the pump does not operate, replace the fuel pump.

    REASSEMBLY
    1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
    (a) Apply a light coat of gasoline or spindle oil to a new O-ring, then install it onto the fuel pressure regulator.
    Fuel Pressure Regulator O-Ring.jpg

    (b) Apply a light coat of gasoline or spindle oil to the O-ring again, then push the fuel pressure regulator into the fuel tank fuel filter.

    NOTICE:
    Make sure that the O-ring is not cracked or jammed when installing.

    2. INSTALL FUEL PUMP FILTER
    (a) Install the fuel pump filter onto the fuel pump.
    (b) Install a new clip.
    3. INSTALL FUEL PUMP
    (a) Apply a light coat of gasoline or spindle oil to the Oring.
    (b) Push the fuel pump into the fuel tank fuel filter.

    NOTICE:
    Make sure that the O-ring is not cracked or jammed when installing.

    4. INSTALL FUEL PUMP CUSHION RUBBER
    (a) Install the fuel pump cushion rubber onto the fuel pump.
    5. INSTALL NO. 2 FUEL SUCTION SUPPORT
    (a) Align the claw positions, then install the fuel suction support onto the fuel filter.
    6. INSTALL FUEL PUMP HARNESS
    (a) Connect the pump harness connector.
    (b) Install the 2 pump harness terminals.
    7. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
    (a) Apply a light coat of gasoline or spindle oil to the O-ring of the fuel suction plate.
    (b) Align the claw positions, then install the fuel suction plate into the fuel filter.

    NOTICE:
    Make sure that the O-ring is not cracked or jammed when installing.

    (c) Connect the fuel pump harness connector.
    8. INSTALL FUEL SENDER GAUGE ASSEMBLY
    (a) Slide the fuel sender gauge to fit the claws.

    INSTALLATION
    1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
    (a) Install a new gasket onto the fuel suction with pump and gauge tube.
    (b) Install the fuel suction with pump and gauge tube into the fuel tank.

    NOTICE:
    • Do not damage the fuel pump filter.
    • Make sure that the fuel sender gauge arm does not bend.

    (c) Install the fuel tank vent tube set plate with the 6 bolts.
    Torque: 6.0 N*m (60 kgf*cm, 53 in.*lbf)
    (d) Install the fuel tank protector plate with the 2 bolts.
    Torque: 6.0 N*m (60 kgf*cm, 53 in.*lbf)
    (e) Connect the fuel tank main tube.

    NOTICE:
    • Check that there are no scratches or foreign objects around the connected part of the fuel tube joint and plug before performing this work.
    • Check that the fuel tube joint is securely inserted to the end.
    • Check that the tube joint clip is on the collar of the fuel tube joint.
    • After installing the tube joint clip, check that
    the fuel tank main tube cannot be pulled out.

    2. INSTALL REAR FLOOR SERVICE HOLE COVER
    (a) Attach new butyl tape to the service hole cover.
    (b) Connect the wire to wire connector.
    (c) Connect the fuel pump connector.
    (d) Install the rear floor service hole cover, making sure it is aligned with the 2 convexes of the floor panel.

    NOTICE:
    Make sure that the rear floor service hole cover does not mount on the convex of the floor panel when installing.

    3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
    4. PERFORM INITIALIZATION

    (a) Perform initialization.

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

    5. CHECK FOR FUEL LEAKS
    6. INSTALL REAR SEAT CUSHION ASSEMBLY
  3. navylife59
    Offline

    navylife59 Super Moderator Staff Member

    Joined:
    Mar 22, 2006
    Location:
    Emory, Texas or Gretna, LA
    Walbro 255LPH In-tank Fuel Pump

    When stepping up to larger injectors 550cc-up and boost over 10PSI, the injectors will become saturated. This is due to the stock fuel pump not being able to handle the flow of the larger injectors and keep the fuel rail pressurized. This is largely an issue with the return-less fuel system on the tC. Installing a higher volume pump to keep up with the fuel demand on these setups and allow the injector Duty Cycles to be turned down. Of course, increasing boost and going larger than 550cc injectors will eventually get you back to saturated injector driver circuits. At this point, only a return system will work for you.

    The install of a Walbro pump is very simple. Following the instruction above, you will need to only make 2 small modifications.
    1. The Walbro pump pigtail will have to be spliced into factory harness.
    Only high-end crimp connectors that are self sealing shall be used if fuel or fuel vapors exist.
    If no fuel or vapors, then solder the leads and utilize high grade shrink tubing.
    2. It is necessary to remove the fuel pump cushion rubber and discard. This makes room for the Walbro pump which is slightly longer.

    Fuel Pump-Filter Assembly.jpg
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