Fuel Filter: Service and Repair

NOTE: The Fuel Filter for this vehicle is a 'Maintenance-Free item', and does not require routine service.

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY




Component

Removal and Installation

REMOVAL

WARNING: Be sure to read "General Precautions" before working on the fuel system. Refer to "General Precaution".




1. Check fuel level with the vehicle on a level surface. If the fuel gauge indicates more than the level as shown (7/8 full), drain fuel from the fuel tank until the fuel gauge indicates level as shown (7/8 full).

NOTE: Fuel will be spilled when removing fuel pump assembly if fuel level is above the fuel pump assembly installation surface.

- As a guide, fuel level is at the level as shown or below when approximately 12 l (3 1/8 US gal, 2 5/8 Imp gal) of fuel is drained from a full fuel tank.
- In case fuel pump does not operate, perform the following procedure.

a. Insert fuel tubing of less than 25 mm (0.98 in) in diameter into fuel filler tube through fuel filler opening to drain fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to "Fuel Tank".
c. Insert fuel tubing into fuel tank through fuel filler hose to drain fuel from fuel tank.

2. Open fuel door and unscrew the fuel filler cap to release the pressure inside the fuel tank.
3. Release the fuel pressure from the fuel lines. Refer to EC-78 "Fuel Pressure Check". Testing and Inspection
4. Remove rear seat bottom.
5. Turn the four retainers 90 degree in a clockwise direction and remove the fuel pump inspection hole cover.




6. Disconnect electrical connector (A) and fuel feed hose quick connector (B).
- Fuel feed hose (1)

- Disconnect the quick connector using the following procedure.




- Hold the sides of the connector, push in tabs and pull out the tube.
- If quick connector and tube on fuel pump assembly are stuck, push and pull several times until they move. Disconnect them by pulling.

CAUTION:
- The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.
- Do not use any tools to remove the quick connector.
- Keep resin tube away from heat. Be especially careful when welding near the resin tube.
- Prevent acid liquid such as battery electrolyte, from getting on resin tube.
- Do not bend or twist resin tube during installation and removal.

- To keep the connecting portion clean, free of foreign materials and to avoid damage, cover them completely with plastic bags or something similar.
- Do not insert plug to prevent damage to O-ring in quick connector.




7. Remove the lock ring using Tool as shown.

Tool number : KV991J0090 (J-46214)

8. Remove fuel level sensor unit, fuel filter and fuel pump assembly (1).

CAUTION:
- Do not bend float arm during removal.
- Do not allow foreign materials to fall into fuel tank. Use a lint free cloth when handling components.
- Avoid impacts such as dropping when handling components.

INSPECTION AFTER REMOVAL
Make sure that the fuel level sensor unit, fuel filter and fuel pump is free from defects and foreign materials.

INSTALLATION
Installation is in the reverse order of removal.

Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
1. Install O-ring to fuel tank without twisting.




2. Install fuel level sensor unit with aligning mating marks (A) on fuel tank and fuel level sensor unit as shown.




- Turn the lock ring (1) until the lock ring is fully rotated into the fuel tank lock tabs (A) as shown.

Quick Connector
Connect fuel feed tube quick connector using the following procedure.

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 using the following procedure.
- Visually confirm that the two retainer tabs are secured to the connector.




- Pull the tube and the connector to make sure they are securely connected.

4. Connect electrical harness connector.

Inspection Hole Cover
- Before installing inspection hole cover, confirm that there are no fuel leaks. Refer to "INSPECTION AFTER INSTALLATION".

1. Install inspection hole cover with the front mark (arrow) facing front of vehicle.
2. Lock clips by turning counterclockwise.

INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.

1. Turn ignition switch "ON" (without starting the engine), to check the connections for fuel leaks with the electric fuel pump applying pressure to the fuel piping.
2. Start the engine and let it idle to check that there are no fuel leaks at the fuel system connections.