Removal and Installation

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY


Exploded View















FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY


Removal and Installation


WARNING:
Be sure to read "General Precautions" when working on the fuel system. General Precautions.

REMOVAL
1. 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 20 liters from a full-tank condition.

- In the event of malfunction in fuel pump, insert a hose measuring 20mm (0.79 in) in diameter into the filler opening to draw approximately 20 liters fuel.
2. Release the fuel pressure from the fuel lines. Testing and Inspection.
3. Open fuel filler lid.
4. Open filler cap and release the pressure inside fuel tank.
5. Tilt the second seat toward the front of the vehicle.





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

A : Direction mark





7. Disconnect harness connector (1) and all the fuel tube.

2 : Fuel feed tube
3 : Quick connector

Disconnect quick connector as follows:





- Hold the sides of connector, push in tabs and pull out fuel feed tube.

A : Pull
B : Push in tabs

- 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.

B : Connection (Cross-section)
D : To under floor fuel line
E : To fuel tank
G : Disconnection

- 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 lock ring for fuel level sensor unit, fuel filter and fuel pump assembly with fuel tank lock ring wrench [SST:
KV10119800 (J-45722)] (A) by turning counterclockwise.
9. Remove fuel level sensor unit, fuel filter and fuel pump assembly.

CAUTION:
- Never bend float arm during removal.
- Avoid impacts such as falling when handling components.

INSTALLATION
Note to the following, and install in the reverse order of removal.
- For installation, use a new O-ring.

Quick Connector
- Connect quick connector 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, check that the connection is secure by following method.





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

A : Pull

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