Removal and Installation

Removal And Installation:

REMOVAL

WARNING: Read "Service Precautions" before working on the fuel system.

1. Check fuel level on level gauge. If fuel gauge indicates more than the level shown in figure (full or almost full), drain fuel from fuel tank until fuel gauge indicates level shown in figure.




- In case fuel pump does not operate, take following procedure.
a. Insert fuel tube of less than 15 mm (0.59 in) in diameter into fuel filler tube through fuel filler opening to draw fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to "FUEL TANK".
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
- As a guide, fuel level becomes the position shown in figure when approximately 20 liter (5-1/4 US gal, 4-3/8 Imp gal) of fuel are drained from fuel tank.

3. Open fuel filler lid.
4. Open the filler cap and release the pressure inside the fuel tank.
5. Remove the rear seat cushion. Refer to "Removal and Installation".




6. Peel off floor carpet, then remove inspection hole cover for main and sub fuel level sensor unit, turning clips by 90 degrees clockwise.




7. Disconnect the harness connector and fuel feed tube.




Disconnect the quick connector as specified:
- Hold the sides of the connector, push in tabs and pull out the tube.
- If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling.

CAUTION:




- The quick connector can be disconnected when the tabs are completely depressed. Do not twist it more than necessary.
- Do not use any tools to disconnect the quick connector.
- Keep the resin tube away from heat. Be especially careful when welding near the tube.
- Prevent acid liquid such as battery electrolyte, etc. from getting on the resin tube.
- Do not bend or twist the resin tube during installation and disconnection.
- Do not remove the remaining retainer on the hard tube (or the equivalent) except when the resin tube or the retainer is replaced.
- When the resin tube or hard tube (or the equivalent) is replaced, also replace the retainer with a new one (White colored retainer).




- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.




8. Remove main fuel level sensor unit, fuel filter and fuel pump assembly, and sub fuel level sensor unit as specified.

CAUTION:
- Do not bend the float arm during removal.
- Avoid impacts such as falling when handling components.
a. Removal of main fuel level sensor unit, fuel filter and fuel pump assembly:
i. Remove retainer.
ii. Raise the main fuel level sensor unit, fuel filter and fuel pump assembly, and using a snap ring pliers, remove the fuel hose connector.

CAUTION: Be careful not to damage fuel hose connector by expanding them excessively.

b. Removal of sub fuel level sensor unit:
i. Remove retainer.
ii. Raise and release the sub fuel level sensor unit to remove.


INSTALLATION
Install in the reverse order of removal paying attention to the following.




- When installing fuel hose connector, insert them fully until a click sound of full stopper engagement is heard.




- Face main fuel level sensor unit, fuel filter and fuel pump assembly and sub fuel level sensor unit as shown in figure, and install them with knock pin on back aligned with pin hole on fuel tank.




- Install retainer so that its notch becomes parallel with notch on fuel tank.
- Tighten retainer mounting bolts evenly.
- Connect the quick connector as follows.




1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a click is heard.
3. After connecting, make sure that the connection is secure by following method.
4. Pull the tube and the connector to make sure they are securely connected.
- Visually confirm that the two retainer tabs are connected to the connector.

INSPECTION AFTER INSTALLATION
- Use the following procedure to check for fuel leaks.
1. Turn ignition switch ON (do not start engine), then check connections for leaks by applying fuel pressure to fuel piping.
2. Start the engine and rev it up and make sure there are no fuel leaks at the fuel system connections.