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 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 fuel level sensor units for the top of the fuel is above the fuel level sensor units installation surface.
- As a guide, fuel level becomes the position as shown in the figure or below when approximately 25 l (6-5/8 US gal, 5-1/4
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. .
c. Insert hose into fuel tank through fuel filler hose to draw fuel from fuel tank.
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: KV99110600 (J-46214)] turning counter clockwise.
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.
1. Install O-ring to fuel tank without twist.
Arrow Indicates : Vehicle front
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.
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: KV99110600 (J-46214)] 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.