Removal And Installation

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

2WD : Removal and Installation


WARNING:
Read "General Precautions" when working on the fuel system. General Precautions.

REMOVAL

1.Release the fuel pressure from the fuel lines. Testing and Inspection.
2.Check fuel level on a level ground. If the fuel level is 7/8 of the fuel tank (full or nearly full), draw appropriate amount of fuel from the fuel tank.

Guideline : Draw approximately 25 liters (6-5/8 US gal, 5-1/4 Imp gal) from a full-tank condition.

- In the event of malfunction in fuel pump, insert a hose measuring 25 mm (0.98 in) in diameter into the filler opening to draw approximately 25 liters fuel.
3.Open fuel filler lid.
4.Open filler cap and release the pressure inside fuel tank.
5.Remove rear seat. Exploded View.
6.Remove inspection hole cover.





7.Disconnect harness connector (1) and quick connector (2).





- Remove quick connector in the following procedures.





- Pinch quick connector square-part (A) with your fingers, and pull out the quick connector (1) by hand.
- If quick connector and tube on sender unit are stuck, push and pull several times until they move, and pull out.

CAUTION:
- Quick connector can be removed when the tabs are completely depressed. Never twist it more than necessary.
- Never use any tools to disconnected 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.
- Never bend or twist resin tube during installation and disconnection.





- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags (A) or something similar.
- Never insert plug, preventing damage on O-ring in quick connector.





8.Remove lock ring for fuel level sensor unit, fuel filter and fuel pump assembly with lock ring wrench (A) [SST: KV-99110600 (J46214)] turning counterclockwise.
NOTE:
For reference when installing, put a matching mark on lock ring, fuel pump assembly and fuel tank.





9.Raise fuel level sensor unit, fuel filter and fuel pump assembly (1).

CAUTION:
- Never bend float arm during removal.
- Never pollute the inside by residue fuel. Draw out avoiding inclination by supporting with a cloth.
- Never cause impacts such by dropping when handling components.

INSTALLATION

Note to the following, and install in the reverse order of removal.

CAUTION:
Do not reuse O-rings.
1.Install O-ring to fuel tank without twist.

CAUTION:
Do not reuse O-ring.





2.Install fuel level sensor unit, fuel filter and fuel pump assembly (1) with its matching mark (A) aligned with fuel tank matching mark (B) as shown in the figure.

White arrow indicates : Vehicle front

CAUTION:
Never bend float arm during installing.





3.Install lock ring for fuel level sensor unit, fuel filter and fuel pump assembly with lock ring wrench (A) [SST: KV-99110600 (J46214)] turning clockwise.
4.Connect quick connector of fuel feed tube as per following procedures.
a.Check the connection for damage or any foreign materials.
b.Align the connector with the tube, then insert the connector straight into the tube until a click sound is heard.
c.After connecting, check that the connection is secure by following method.
- Visually confirm that the two tabs are connected to the connector.





- Pull (A) the tube and the connector to check they are securely connected.