Relieve pressure in the fuel system.
Remove the cap from the fuel tank filler neck.
Turn off the ignition and disconnect the ground wire from the battery.
Figure 5.6. Fuel pump on vehicles manufactured before 2001: 1 – gasket; 2 – fuel pump/fuel level sensor unit; 3 – fuel return hose; 4 – gasket; 5 – Electrical connector of fuel pump/fuel level sensor; 6 – cover closing the opening for servicing the fuel pump/fuel level sensor; 7 – gasket; 8 – fuel supply pipe; 9 – fuel filter; 10 – fuel supply hose; 11 – sealing ring; 12 – fuel pressure regulator; 13 – clamp
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Figure 5.7. Fuel pump on vehicles produced since 2001: 1 – gasket; 2 – fuel pump/fuel level sensor unit; 3 – electrical connector of the fuel vapor pressure sensor; 4 – fuel tank cap; 5 – Electrical connector of the fuel pump/fuel level sensor; 6 – cover closing the opening for servicing the fuel pump/fuel level sensor; 7 – main fuel tank pipe; 8 – retainer; 9 – fuel intake plate; 10 – fuel pump mounting belt; 11 – fuel filter block; 12 – lid; 13 – tube; 14 – fuel pump; 15 – clamp; 16 – rubber cushion; 17 – support; 18 – auxiliary fuel suction hose
To access the fuel pump/level sensor assembly, remove the rear seat and the cover covering the fuel pump/level sensor service opening (figure 5.6, 5.7).
Disconnect the electrical connector from the fuel pump/fuel level sensor assembly. Disconnect the fuel lines and, if equipped, the fuel vapor pressure sensor electrical connector.
Remove the fuel pump/fuel level sensor block cover mounting bolts.
Figure 5.8. Attachment location of the auxiliary fuel suction hose to the fuel pump/fuel level sensor unit on models from 2001 onwards
Carefully remove the fuel pump/fuel level sensor assembly from the fuel tank. On 2001 and later models, after the fuel pump/fuel level sensor assembly is out of the fuel tank, disconnect the auxiliary fuel suction hose from the bottom of the assembly (figure 5.8).
Disconnect the electrical connector from the fuel pump.
Remove the fuel pump from the block.
Figure 5.9. Removing the lower part of the fuel pump from the bracket on models before 2001
On pre-2001 models, loosen the clamp and remove the hose, then remove the lower portion of the pump from the bracket (figure 5.9).
On 2001 and later models, disconnect the fuel level sender by moving the pump away from the fuel pickup plate.
Remove the fuel filter and suction plate from the retainers.
Disconnect the electrical connector from the fuel pump.
Figure 5.10. Location of the fasteners securing the fuel line to the fuel pump on models produced before 2001
Figure 5.11. Disconnecting the fuel pump mounting belt and separating the pump from the block on models produced since 2001
Remove the upper bracket and fuel line from the pump retainers (figure 5.10), disconnect the fuel pump mounting belt (figure 5.11) and separate the pump from the block.
Using a thin screwdriver blade, remove the fuel pickup and rubber pad from the bottom of the fuel filter.
Figure 5.12. Location of the spring clamp securing the mesh filter to the fuel pump
Remove the spring clip and the strainer from the fuel pump (figure 5.12).
Install the fuel pump in the reverse order of removal.