Fuel pump replacement

If the engine power drops, there is increased noise, or howls are periodically heard when the fuel pump is running, then most likely the fuel pump is out of order.

Pre-check the pressure in the fuel supply system in the following order.

1. Check the fuel pressure regulator (see «Checking and replacing the fuel pressure regulator»).

2. If the system pressure is less than 250 kPa (2.5 kgf/cm²), replace the fuel filter (see «Fuel filter replacement»).

If in this case the pressure does not increase, the fuel pump must be replaced, since the pump has a difficult-to-disassemble design and its elements are not supplied separately as spare parts.

You will need: a flat-blade screwdriver, a container to drain the fuel from the fuel pump module.

1. Reduce the pressure in the supply system (see «Reducing the pressure in the power system»).

2. Disconnect the wire from the terminal «minus» battery.

3. Remove the fuel tank (see «Fuel tank replacement»).



4. Unscrew the pressure ring of the fuel pump module by setting the handles of the pliers, as shown in the photo..



5.... and remove the ring.




6. Carefully remove the fuel pump module and drain the fuel from it into a prepared container.



7. Remove the seal.

Note. Be sure to replace the gasket if it is torn or severely compressed.

8. Disconnect the block from the terminal on the cover of the fuel pump module housing...




9.... and from the fuel level sensor.



10. Squeeze the ends of the clamp and remove the fuel level sensor.



11. Press the latches on the housing of the fuel pump module with a screwdriver..



12.... one latch inside..




13.... and disconnect the fuel pump module housing.



14. Remove the spacer ring.



15. Pry with a screwdriver..



16.... and remove the filter from the pump.

Note. Carefully inspect the filter for mechanical damage and contamination, if necessary, wash or replace the fuel inlet filter.

17. Disconnect the wiring harness block from the fuel pump.



18. Unclench a collar of fastening of a hose to a branch pipe of the fuel pump and remove the fuel pump.

Note. The hose clamp is disposable, replace it with a new one when reassembling.

19. Assemble and install the fuel pump module in the reverse order of removal.

Note. Apply some silicone grease to the inside of the pressure ring to make it easier to install.

Note. Make sure that when installing the module, the marks on the fuel tank, the clamping ring and on the fuel pump module housing coincide.