How do I hook up the fuel hoses when reassembling from macanical to a universal fuel pump ??

Removing and reinstalling the injector pump on a Hino Dutro SO5D engine requires careful attention to detail to avoid damaging the components. Here's a general guide on how to perform this task:
Tools and Materials Needed:

• Basic mechanic's toolset
• Replacement gaskets and seals (if necessary)
• Clean rags
• Diesel fuel-safe sealant (if necessary)
• Torque wrench

Procedure:

1. Prepare the Engine:
   • Park the vehicle on a flat, level surface and engage the parking brake.
   • Disconnect the negative terminal of the battery to prevent accidental starting.
   • Remove any components obstructing access to the injector pump, such as air intake hoses or covers.
2. Drain the Fuel System:
   • Relieve the fuel pressure in the system by loosening the fuel line fittings at the injector pump and allowing any residual pressure to escape.
   • Place a suitable container underneath to catch any spilled fuel.
   • Disconnect the fuel lines from the injector pump.
3. Disconnect Electrical Connections:
   • Disconnect any electrical connections, such as wiring harness connectors or sensor connections, from the injector pump.
4. Remove the Injector Pump:
   • Loosen and remove the mounting bolts securing the injector pump to the engine block. Take note of their locations and lengths as they may vary.
   • Carefully lift the injector pump away from the engine, ensuring not to damage any surrounding components.
   • Place the injector pump on a clean work surface.
5. Install the New Injector Pump:
   • Position the new injector pump in place on the engine block, aligning it with the mounting holes.
   • Install and tighten the mounting bolts to the specified torque settings. Refer to the manufacturer's specifications for the correct torque values.
   • Reconnect any electrical connections and fuel lines to the injector pump.
6. Reassemble Components:
   • Reinstall any components that were removed to access the injector pump, such as air intake hoses or covers.
   • Ensure all connections are properly secured and tightened.
7. Refill the Fuel System:
   • Prime the fuel system to remove any air by using the vehicle's priming mechanism or manually bleeding the system.
   • Check for any fuel leaks around the injector pump and fuel lines.
8. Test Operation:
   • Reconnect the negative terminal of the battery.
   • Start the engine and monitor for any abnormal noises or vibrations from the injector pump.
   • Verify that the engine runs smoothly and there are no fuel leaks.

RTM ,. read the shop manual first.? its all there to read 24/7.
Is this car A USA CAR?

generic.

1. drain tank fully, or you will get a flood of fuel on YOU.
2. remove all hoses to tank/vents and wires, to pump rack top,.
3. remove filler neck hose to tank.
4. with a floor jack under tank, and wood protector to it, try to raise tank just a tad. (1/2?") (I have car at rear on jack stands first)
5. remove tank straps. now.
6. lower jack, done.

now out of shop manual quoted SX4 , near.

1) Relieve fuel pressure in fuel feed line according to
"Fuel Pressure Relief Procedure".
2) Disconnect negative cable at battery.
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler
hose (1) and drain fuel in space "A" as shown in
figure.(this car has check valve at tank inlet)
Hoist vehicle, and remove clamp (2), fuel filler hose
(1) and breather hose (3) from fuel filler neck.
6) Remove exhaust center pipe referring to "Exhaust
Pipe and Muffler Removal and Installation in Section
1K".
7) Remove propeller shaft (For 4WD model) referring to
"Propeller Shaft Assembly Removal and Installation
in Section 3D".
8) Due to absence of fuel tank drain plug, drain fuel
tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
Disconnect quick joint (fuel pipe) (1) from fuel pipes
(2) referring to "Fuel Hose Disconnecting and
Reconnecting".
10) Support fuel tank (1) with jack (2) and remove its
mounting bolts (3)
Lower fuel tank a little as to disconnect wire harness
at connector (1)and ground wire (2), then remove
fuel tank

Take it to a qualified repair shop . Has no reset switch .

You have to empty the fuel tank somehow (siphon the gasoline out into a fuel can so it doesn't sit around and cause fumes to concentrate where they could be ignited). Jack the rear axle of the car up and put it on jack stands for safety. Disconnect the filler line and fuel lines that go toward the front of the car from the fuel tank, unbolt the 2 straps holding the fuel tank, lower the fuel tank (take care not to damage any of the lines or hoses as it comes down, take off the locking ring, remove the fuel fuel sending assembly, disassemble it, then reassemble with the new fuel pump, place the assembly back into the tank and put the locking ring back on, then put the fuel tank back in, reconnect the fuel lines, fill the tank with just a few gallons, test to see if it starts, take it off jack stands. More details here:http://www.ehow.com/how_7532750_replace-2001-pontiac-grand-prix.html

Try breaking fuel line into pump and bleeding fuel into bucket, if your happy that there is no airlock, reconnect and try again. have you checked your fuel filter?

see instructions from AutoZone:
The fuel pump assembly is located in the fuel tank. Refer to the fuel tank assembly illustrations in this section. On most applications, the fuel tank must be lowered to remove the fuel pump assembly. The fuel pump assembly is cooled by the fuel in the tank.

REMOVAL & INSTALLATION


See Figure 1

1. Before disconnecting the fuel lines or any of the fuel system components, release the fuel system pressure as described previously in this section. Releasing system pressure is a very important step for the correct removal of the electric fuel pump.

Fig. Fig. 1: Internal view of the electric fuel pump

1. Disconnect the negative battery cable. Unfasten the fuel pump assembly electrical connector and remove the fuel tank inspection cover.

If the truck has no fuel tank inspection cover, the fuel tank must be lowered or removed to gain access to the in-tank fuel pump.

1. Disconnect the fuel outlet and return hoses. Remove the fuel tank assembly, if necessary.
2. Remove the ring retaining bolts and the O-ring, then lift the fuel pump assembly from the fuel tank. Plug the opening with a clean rag to prevent dirt from entering the system.

When removing or installing the fuel pump assembly, be careful not to damage or deform it. Always install a new O-ring.
To install:

1. Install the fuel pump assembly in the fuel tank with a new O-ring. Install the ring retaining bolts. Install the fuel tank if removed.
2. Reconnect the fuel lines and fasten the electrical connection.
3. Connect the battery cable, then start the engine and check for fuel leaks.

The "Check Engine Light'' may stay on after installation is completed. If so, the trouble code in the control unit's memory must be erased. To erase the code, disconnect the battery cable for 10 seconds, then reconnect it a verify that the light is extinguished.

TESTING


See Figures 2 and 3

1. Relieve the fuel system pressure, as described previously in this section.
2. Disconnect the fuel inlet hose at the electro injection unit.

Fig. Fig. 2: Make sure that the fuel line hose clamps are installed properly



Fig. Fig. 3: Testing fuel system pressure using a gauge and a "T'' fitting

1. Install a fuel pressure gauge.
2. Start the engine and check the fuel line for leakage.
3. Read the pressure on the pressure gauge. The gauge should read approximately 36.3 psi (250 kPa).
4. Relieve the fuel system pressure again.
5. Remove the pressure gauge from the fuel line and reconnect the fuel inlet hose.

REMOVAL & INSTALLATION

See Figure 1


Fig. Fig. 1: Fuel pump assembly mounted under the vehicle-1.8L engine

1. Release the fuel system pressure. Do not reconnect the fuel pump harness.
2. Disconnect the negative battery cable.
3. Raise and support the vehicle safely on jackstands.
4. Clamp the middle portion of the hose connecting the fuel tank pipe and the pump to prevent fuel from flowing out of the tank when unfastened.
5. Loosen the hose clamp and disconnect the hose.
6. Remove the three pump bracket mounting bolts and remove the pump together with the pump damper.

To install:

1. Install the fuel pump and damper, and tighten the bolts securely.
2. Install the hose and tighten the clamp screw to 9-13 inch lbs. (1.0-1.5 Nm).
3. Install the pump bracket in position to the vehicle body and secure it with the bolts.

Take care to position the rubber cushion properly.

1. Connect the pump harness.
2. Connect the negative battery cable and test the fuel pump for proper operation.
3. Check for fuel leaks.

TESTING

1. Turn the ignition ON and listen for the fuel pump to make a growling sound. Turn the ignition OFF .
2. Release the fuel system pressure. Disconnect the pump harness and crank the engine for 5 seconds or more. If the engine starts, allow it to run until it stops. Turn the ignition OFF and install the fuel pump connector.
3. Disconnect the fuel hose at the fuel pump.
4. Connect a gauge in-line using a T-fitting.
5. Start the engine and measure the fuel pressure. If the fuel pressure is not 36-50 psi (248-344 kPa), replace the pump.
6. Release the fuel system pressure and remove the gauge.

1992-96 Models
See Figure 6
Be sure this procedure is done in a well ventilated area.

1. Disconnect the negative battery cable.
2. Relieve the fuel pressure.
3. Remove the rear seat cushion.
4. Remove the floor service hole cover.
5. Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there.

fuel pump and sending unit cover

1. Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
2. Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet

pipe from the pump bracket.

1. Remove the pump bracket attaching screws.
2. Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
3. Remove the nut and spring washer, then disconnect the wires from the pump bracket.
4. Remove the sending unit attaching screws, then remove the unit from the bracket.
5. Pull the lower side of the fuel pump from the bracket.
6. Unplug the connector to the fuel pump.
7. Disconnect the hose from the pump.
8. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
9. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
10. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.

To install:

1. Install the pump filter using a new clip. Install the rubber cushion under the filter.
2. Connect the outlet hose to the pump, then attach the pump to the bracket and tighten to 22-25 ft. lbs. (29-34 Nm).
3. Engage the connector to the fuel pump.
4. Install the fuel sending unit to the pump bracket.
5. Install the fuel pump and bracket assembly onto the tank. Use new gaskets. Tighten the pump bracket retaining screws to 34 inch lbs. (4 Nm).
6. Connect the return hoses to the pump bracket.
7. Install the service hole cover, then the engage the fuel pump and sending unit connector.
8. Install the rear seat cushion.
9. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.

Replace Fuel Pump for 1997 Nissan Quest

(1) If the fuel tank has more than one third full, you need to get the gasoline out. If it has one third or less full, you can leave it in the tank. However be very careful around the working area. Make sure you have read fire precautions in a general repair book. Take the fuel pump fuse out from the fuse box near the battery. Run starter for a few seconds. This will remove the fuel pressure in the gas lines. Disconnect battery at negative terminal. Jack up the rear of the van.

(2) Remove the fuel tank protector.


(3) Disconnect fuel pipes at the front end of the fuel tank. Use short pencils and extra rubber hoses to block disconnected pipes and hoses.
There are two pipes connected to the gasoline filler at the side of the van. Disconnect only the smaller one. The larger one is flex enough for the tank to be lowered.

(4) Disconnect the electrical from this connector. Jack the rear end of the fuel tank with a car jack and a piece of 2x4. Put the wood between the jack point and the tank. Then unbolt the two bolts showing in the picture.

(5) Lower the jack after the bolts are removed. The rear end of the tank should be lowered.




(6) Disconnect fuel lines on top of the fuel pump. Reconnect each short hose back to different pipes as shown in picture to block the pipes.

(7) Loose the six mounting bolts on the fuel pump assembly. The bolts should be loosen a little at a time in multiple turns. Also detach the electrical wire holders. After all bolts are removed, carefully take the assembly out of the tank.


(8) Remove the fuel pump from the assembly as shown in picture. Then unplug the electrical wires. Note that two connectors are in different sizes, so that you will not be able to reconnect to a wrong terminal.

(9) Put the new pump and new filter in. Reconnect the electrical wires. If necessary use a pair of pliers to make the connectors tighter. Make sure they are not loose. Reconnect gas inlet to the pressure regulator.

(10) Use a new O ring, put back the assembly to the fuel tank. Make sure the float of the fuel level senser is free, and the assembly is at the right orientation (as shown in picture). Screw back the 6 bolts after making sure the O ring is in right place. The bolts should be tightened in turns. Do not over tighten them. Then reconnect the fuel lines and make sure every fastener is tight. Put the electrical wire into holders.

(11) Jack up the tank and put the two mounting bolt in. (see picture in step 4). Make sure they are tightened with specific torque. Reconnect the electrical connector.

(12) Reconnect two fuel lines at the front side of the tank. Refer to the picture in step 2. Reconnect the hose to the gasoline filler. Before you have a try start, double check if all fuel lines are securely connected and tightened.

(13) Start the engine. You need to crank more than a normal start because the lines were empty. The pressure is built up in some time.

(14) If engine starts ok, turn it off. Then check under the van if there is any leakage. If everything is fine put back the tank protector. (picture in step 2).