Removal and Installation

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY


Removal and Installation


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

REMOVAL
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 fuel gauge indicates level as shown in the figure or below.






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 or below when approximately 20 (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 Exploded View.
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
2. Release the fuel pressure from the fuel lines. Refer to Testing and Inspection.
3. Open fuel filler lid.
4. Open filler cap and release the pressure inside fuel tank.
5. Remove rear seat cushion. Refer to Exploded View.





6. Peel off floor carpet, and then remove inspection hole cover (1) units by turning clips (2) clockwise by 90 degrees.

Right side : Main fuel level sensor unit, fuel filter and fuel pump assembly
Left side : Sub fuel level sensor unit






7. Disconnect harness connector (3) and fuel feed tube (2).

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 main fuel level sensor unit, push and pull quick connector several times until they start to move. Then disconnect them by pulling.

CAUTION:
- Quick connector (1) can be disconnected when the tabs
(F) are completely depressed. Never twist it more than necessary.
- Never use any tools to disconnected quick connector.
- Keep resin tube (C) 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.
- Never remove the remaining retainer (2) on hard tube (or the equivalent) (A) except when resin tube or retainer is replaced.
- When resin tube or hard tube (or the equivalent) is replaced, also replace retainer with new one.





- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags (A) 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:
- Never bend 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 main fuel level sensor unit, fuel filter and fuel pump assembly, and disconnect quick connector as follows:





- Push in tabs (1) and pull out fuel tube (2).
b. Removal of sub fuel level sensor unit:
i. Remove retainer.
ii. Raise and release sub fuel level sensor unit to remove.

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

Fuel tube
- When installing fuel tube (1), refer to "Quick Connector".






Main and Sub Fuel Level Sensor Unit
- Face main and sub fuel level sensor units as shown in the figure, and install them with the knock pin (C) 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 as follows:
1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, and then insert the connector straight into the tube until a click sound is heard.
3. After connecting, check that the connection is secure by following method.





- Pull the tube and the connector to check they are securely connected.
- Visually confirm that the two retainer tabs are connected to the connector.