Removal And Installation

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

Removal and Installation


REMOVAL


WARNING:
Read "General Precautions" before working on the fuel system.
Refer to "General Precautions" General Precautions.
1.Disconnect the battery negative terminal."Removal and Installation (Battery)" Removal And Installation.
2.Unscrew the fuel filler cap to release the pressure inside the fuel tank.
3.Release the fuel pressure from the fuel lines. Refer to "Work Procedure" Testing and Inspection (QR25DE), "Work Procedure" Testing and Inspection (VQ35DE).
4.Remove the rear seat cushion. Refer to "Removal and Installation Seat Assembly" Seat Assembly.
5.Turn the four retainers (A) 90� in a clockwise direction and remove the fuel pump inspection hole cover.






White arrow indicates : Front






6.Disconnect the fuel level sensor unit, fuel filter and fuel pump assembly harness connector (C), EVAP hose quick connector (A), and the fuel feed hose quick connector (B) from the fuel level sensor unit, fuel filter, and fuel pump assembly.

White arrow indicates : Front






Remove the quick connector as follows:
- 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 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 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 tube during installation and removal.
- Only when the tube is replaced, remove the remaining retainer on the tube or fuel level sensor, fuel filter, and fuel pump assembly.
- When the tube or fuel level sensor, fuel filter, and fuel pump assembly is replaced, also replace the retainer with a new one (green colored retainer).





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





7.Remove the lock ring using a socket drive handle and Tool (A).
Tool number: KV991J0090 (J-46214)

CAUTION:
Discard the lock ring if damaged or distorted.

White arrow indicates : Front






8.Remove the fuel level sensor, fuel filter, and fuel pump assembly (A). Remove and discard the O-ring.

CAUTION:
- Do not bend the float arm during removal.
- Discard the O-ring. Do not reuse O-ring.

INSPECTION AFTER REMOVAL

Inspect the fuel level sensor, fuel filter, and fuel pump assembly for any defects and foreign materials. Replace as necessary.

INSTALLATION

Installation is in the reverse order of removal.





- Install the fuel level sensor, fuel filter, and fuel pump assembly with the fuel feed hose (B) facing the left side of the vehicle as shown.
Use a new O-ring.

CAUTION:
Do not reuse O-ring.

White arrow indicates : Front






- Connect the quick connector as follows:
- Check the connection for damage or any foreign materials.
- Align the connector with the tube, then insert the connector straight into the tube until a click is heard.
- After the tube is connected, make sure the connection is secure by performing the following checks:
- Pull the tube and the connector to make sure they are securely connected.





- Visually confirm that the two retainer tabs are connected to the quick connector.