Repair 7

Remove the filler cap on the fuel tank to relieve the vapor pressure in the fuel tank. Take the relay for the fuel pump out of the fuse box located in the engine compartment.

Start the engine and let it run until it stalls. Repeat this procedure until the engine fails to start to ensure you have removed the fuel from the fuel system. Detach the cable from the batterys negative terminal with a socket wrench to ensure you dont start the engine while replacing the fuel pump.

Press down on the quick-connect fittings for the fuel line and disconnect the fuel line from the fuel filter. Hold the locking spring tab on the fuel filter down and turn the fuel filter 90 degrees counterclockwise. Detach the fuel filter from the fuel pump and discard the fuel filters O-rings.

Lubricate the new fuel filter O-rings with engine oil and place them on the fuel filter. Place the fuel filter into its socket on the fuel pump so that the the hold-down tabs on the fuel filter align with the fuel pump flanges. Hold the fuel filter down as you turn it 90 degrees clockwise to lock the fuel filter into place.

Connect the fuel line to the fuel filter, then attach the cable to the batterys negative terminal with a socket wrench. Start the engine and check for fuel leaks.

Open the gas cap to relieve the pressure in the fuel tank. Disconnect the negative battery cable with a socket wrench to avoid starting the engine accidentally. Remove the rear seat cushion and disconnect the screws on the service hole cover. Remove the service hole cover.

Detach the electrical wiring to the fuel pump assembly. Disconnect the fuel outlet pipe from the fuel pump bracket with tool SST 09631-22020. Remove the retaining screws for the fuel pump bracket with a socket wrench and detach the return hoses from the fuel pump bracket. Pull the fuel pump assembly from the fuel tank.

Remove the fuel suction support from the fuel pressure regulator with a socket wrench and detach the fuel pressure regulator from the fuel filter. Remove and discard the O-ring for the fuel pressure regulator.

Coat the new O-ring with a thin layer of gasoline and mount it on the new fuel pressure regulator. Attach the fuel pressure regulator to the fuel filter and install the fuel suction support.

Install the fuel pump assembly into the fuel tank and connect the return hoses to the fuel pump bracket. Fasten the retaining screws to the fuel pump bracket and connect the fuel outlet pipe to the fuel pump bracket with tool SST 09631-22020.

Attach the electrical wiring for the fuel pump assembly. Replace the service hole cover and fasten the retaining screws for the cover with a socket wrench. Install the rear seat cushion and connect the negative battery cable.

Remove the cable from the negative battery terminal. Open the filler cap on the fuel tank to release the pressure in the fuel tank.

Connect a fuel pressure gauge to the pressure fitting on the inlet fuel line. Place the bleed hose of the fuel gauge into a container approved for gasoline. Open the valve on the pressure gauge to relieve the pressure in the fuel system. Drain the fuel from the pressure gauge into the container, then disconnect the pressure gauge from the pressure fitting.

Disconnect the outlet resonator for the air cleaner with a socket wrench. Release the retaining clips for the main wiring harness on the front of the engine, then detach the wiring harness.

Remove the vacuum line from the fuel control regulator. Clean the surrounding area with a shop rag. Release the retainer on the fuel return line for the fuel control regulator, then detach the fuel return line. Release the retainer for the fuel control regulator with a socket wrench. Detach the regulator from the fuel rail. Discard the O-ring on the fuel control regulator.

Install a new O-ring to the new fuel control regulator, and coat the O-ring with engine oil. Push the new fuel pressure regulator into its housing on the fuel rail. Attach the retainer for the fuel control regulator, and tighten it to 71 inch-pounds with a torque wrench.

Attach the retainer for the fuel return line to the fuel control regulator. Tighten its retainer screw to 71 inch-pounds with a socket wrench. Connect the fuel return line for the fuel control regulator.

Fasten the filler cap on the fuel tank, and connect the cable for the negative battery terminal with a socket wrench. Turn the ignition on for two seconds to prime the fuel system, then turn it off for 10 seconds. Turn the ignition back on and check for fuel leaks. Connect the engine wiring on the front of the engine, and attach its retaining clips. Install the resonator for the air intake.