Removal and Installation
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYRemoval and Installation
REMOVAL
WARNING: Be sure to read "General Precautions" when working on the fuel system. Refer to "General Precautions".
1. Check fuel level on fuel gauge. If fuel gauge indicates more than the level as shown in the figure (full or almost full), drain fuel from fuel tank until gauge indicates level as shown in the figure.
NOTE: Because fuel will be spilled when removing main and sub fuel level sensor units for the top of the fuel is above the main and sub fuel level sensor units installation surface.
- As a guide, fuel level becomes the position as shown in the figure when approximately 20 l (5-1/4 US gal, 4-3/8 Imp gal) of fuel are drained from fuel tank.
- In a case that fuel pump does not operate, perform the following procedure.
a. Insert hose of less than 25 mm (0.98 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 hose into fuel tank through fuel filler hose to draw fuel from fuel tank.
2. Release the fuel pressure from the fuel lines. Refer to "FUEL PRESSURE RELEASE".
3. Open fuel filler lid.
4. Open filler cap and release the pressure inside fuel tank.
5. Remove woofer or rear floor box mat and rear floor box. Refer to "Removal and Installation of Woofer and Woofer Amp. (BOSE System)" or "LUGGAGE FLOOR TRIM".
6. Remove inspection hole cover for main and sub fuel level sensor units by turning clips clockwise by 90 degrees.
7. Disconnect harness connector and quick connector.
Disconnect quick connector as follows:
- Hold the sides of connector, push in tabs and pull out fuel feed tube.
- If quick connector sticks to tube of fuel level sensor unit, push and pull quick connector several times until it start to move.Then disconnect quick connector by pulling.
CAUTION:
- 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 quick connector.
- Keep resin tube away from heat. Be especially careful when welding near the resin tube.
- Prevent acid liquid such as battery electrolyte, etc. from getting on resin tube.
- Do not bend or twist resin tube during installation and disconnection.
- Do not remove the remaining retainer on hard tube (or equivalent) except when resin tube or retainer is replaced.
- When resin tube or hard tube (or equivalent) is replaced, also replace retainer with new one.
- Replace same color retainer as before replacing.
Retainer color: White
- 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 follows.
CAUTION:
- Do not bend float arm during removal.
- Avoid polluting the inside by residue fuel. Draw out with avoiding inclination by supporting with a cloth.
- 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 main fuel level sensor unit, fuel filter and fuel pump assembly, and using snap ring pliers, remove 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 sub fuel level sensor unit to remove.
INSTALLATION
Note the following, and install in the reverse order of removal.
Main and Sub Fuel Level Sensor Unit
- When installing fuel hose connector insert them fully until a click sound of full stopper engagement is heard.
- Face main and sub fuel level sensor units as shown in the figure, and install them with the knock pin on back aligned with pin hole on fuel tank.
- Install retainer so that its notch becomes parallel with the notch on fuel tank.
- Tighten retainer mounting bolts evenly.
Quick Connector
Connect quick connector of fuel feed hose 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 sound is heard.
3. After connecting, make sure that the connection is secure by following method.
- Visually confirm that the two tabs are connected to the connector.
- Pull the tube and the connector to make sure they are securely connected.
Inspection Hole Cover
1. Install inspection hole cover with direction mark (arrow) facing front of vehicle.
2. Lock clips by turning counter-clockwise.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch "ON" (with engine stopped), then check connections for leaks by applying fuel pressure to fuel piping.
2. Start engine and rev it up and make sure there are no fuel leaks at the fuel system connections.