3-116 FUEL SYSTEM (DFI)

Fuel Pump

Fuel Pump Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF and disconnect the battery (–) terminal.

To make fuel spillage minimum, draw the fuel out from the fuel tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

CAUTION

Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it.

•Draw the fuel out from the fuel tank with a commercially available electric pump.

•Remove the fuel tank (see Fuel Tank Removal).

○Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. Plug the fuel pipe of the fuel tank.

•Turn the fuel tank upside down.

•Unscrew the fuel pump bolts [A], and take out the fuel pump [B].

CAUTION

Do not pull the leads of the fuel pump. If they are pulled, the lead terminals may be damaged.

•Discard the fuel pump gasket [A].

FUEL SYSTEM (DFI) 3-117

Fuel Pump

Fuel Pump Installation

•Remove dirt or dust from the fuel pump [A] by lightly applying compressed air.

•Replace the fuel pump gasket with a new one.

•Check that the fuel pump terminal [A] and band [B] are in place.

•Apply a non-permanent locking agent to the threads of the fuel pump bolts.

•Tighten the fuel pump bolts to a snug fit, following the tightening sequence as shown in the figure.

•Following the tightening sequence, tighten the fuel pump bolts to the specified torque.

Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•Tighten the fuel pump bolts again to check the tightness in the order shown.

Fuel Pump Operation Inspection

NOTE

○Be sure the battery is fully charged.

•Turn the engine stop switch to run position.

•Turn the ignition switch ON and make sure that the fuel pump operates (make light sounds) for 3 seconds, and then stops.

•Turn the ignition switch OFF.

If the pump does not operate as described above, check the operating voltage (see Fuel Pump Operating Voltage Inspection).

3-118 FUEL SYSTEM (DFI)

Fuel Pump

Fuel Pump Operating Voltage Inspection

NOTE

○Be sure the battery is fully charged.

•Turn the ignition switch OFF.

•Remove the front seat (see Front Seat Removal in the Frame chapter).

•Disconnect the fuel pump lead connector and connect the harness adapter [A] between these connectors as shown in the figure.

Main Harness [B] Fuel Pump [C]

Special Tool - Measuring Adapter: 57001-1700

•Connect a digital meter [D] to the harness adapter leads.

Fuel Pump Operating Voltage Connections to Adapter:

Digital Meter (+) → R (pump Y/R) lead Digital Meter (–) → BK (pump BK/W) lead

•Measure the operating voltage with engine stopped and with the connector joined.

•Turn the engine stop switch run position.

•Turn the ignition switch ON.

Operating Voltage

Standard: Battery Voltage for 3 seconds, and then 0 V

•Turn the ignition switch OFF.

If the reading stays on battery voltage and never shows 0 V, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter).

If the fuel pump relay is normal, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).

If there is still no battery voltage, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter).

If the fuel pump relay is normal, check the wiring for continuity (see wiring diagram in this section).

Special Tool - Hand Tester: 57001-1394

If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).

If the reading is in specification, but the pump does not operate, replace the fuel pump (see Fuel Pump Removal/Installation).

FUEL SYSTEM (DFI) 3-119

Fuel Pump

Pressure Regulator Removal

○The pressure regulator [A] is built into the fuel pump and can not be removed.

Fuel Filter Cleaning

○The fuel filter [A] is built into the fuel pump and can not be cleaned or checked.

If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set.

Fuel Pump Circuit

1.Ignition Switch

2.Engine Stop Switch

3.ECU

4.Fuel Pump

5.Fuse Box

6.Ignition Fuse 15 A

7.Frame Ground

8.Battery 12 V 8 Ah

9.Main Fuse 30 A

10.Fuel Pump Relay

11.Relay Box