I30 1996-1997

Fuel Pump

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Removal & Installation



  1. Relieve the fuel system pressure
    CAUTION
    Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the access panel under the rear seat.
    NOTE
    If the vehicle has no fuel pump access cover, the fuel tank must be lowered or removed to gain access to the in-tank fuel pump.

  6.  
  7. Disconnect the fuel gauge electrical connector and pump electrical connector.
  8.  
  9. Disconnect the fuel outlet and the return hoses. If necessary, remove the fuel tank.
  10.  
  11. Remove the fuel pump assembly-to-fuel tank bolts and lift the fuel pump assembly from the fuel tank. Discard the O-ring. Plug the fuel tank opening with a clean rag to prevent dirt from entering the system.
    NOTE
    When removing or installing the fuel pump assembly, be careful not to damage or deform it and always install a new O-ring.

  12.  

To install:

  1. Remove the rag; using a new O-ring, install fuel pump assembly into the fuel tank. Torque the bolts to 1.4-1.9 ft. lbs. (2.0-2.5 Nm). If removed, install the fuel tank assembly
  2.  
  3. Connect the fuel lines and the electrical connectors. Always use new clamps when reconnecting fuel line hoses
  4.  
  5. Install the fuel pump access cover.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check for fuel leaks.
    NOTE
    On some models, the Check Engine Light will stay ON after installation is completed. The memory code in the control unit must be erased. This code is stored for an open fuel pump circuit, this is caused when the fuel pressure is released. To erase the code, disconnect the battery cable for 10 seconds then reconnect after installation of fuel pump.

  10.  

 
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