Removal and Installation

Removal and Installation

REMOVAL

WARNING: Read "Service Precautions" before working on the fuel system.




1. Check fuel level on level place. If gauge indicates more than the level shown in figure (full or almost full) drain fuel from fuel tank until gauge indicates level shown in figure.

- In case of fuel pump does not operate take following procedure.
a. Insert fuel tube of less than 25mm (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 fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.

- As a guide fuel level becomes the position shown in figure when approximately 20 liter (5-1/4 US gal 4-3/8 Imp gal) of fuel are drained from fuel tank.

2. Release the fuel pressure from the fuel lines. Refer to "FUEL PRESSURE RELEASE".
3. Open fuel filler lid.
4. Open the filler cap and release the pressure inside the fuel tank.
5. Remove the rear seat cushion.




6. Peel off floor carpet then remove inspection hole cover for main and sub fuel level sensor unit.




7. Disconnect the harness connector and fuel feed tube.




Remove the quick connector as follows:
- Hold the sides of the connector push in tubs 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 pump assembly.
- When the tube or fuel level sensor unit is replaced, also replace the retainer with a new one (Orange colored retainer).




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




8. Remove main fuel level sensor unit fuel filter and fuel pump assembly and sub fuel level sensor unit.

CAUTION:
- Do not bend the float arm during removal.
- Avoid impacts such as falling when handling components.

Removal of main fuel level sensor unit fuel filter fuel pump assembly:
- Raise the sender unit and remove the jet pump to remove the sender unit.
- Leave the let pump on the fuel tank with the fuel hose.

CAUTION:
- Do not disassemble the jet pump, fuel hose and jet pump inlet assembly. If necessary, replace as a set of fuel tank.

Removal of sub fuel level sensor unit:
- Raise and release the sub fuel level sensor unit to remove.

INSPECTION AFTER REMOVAL
Make sure the fuel pump strainer is free from foreign materials. If any are found remove them.

INSTALLATION
Installation is in the reverse order of removal paying attention to the following.




- When installing the jet pump insert them fully until a click sound of full stopper engagement is heard.




- Face fuel gauge as shown in figure and install it with knock pin on back aligned with pinhole on fuel tank.




- Install retainer so that its notch becomes parallel with notch on fuel tank.
- Tighten retainer mounting bolts evenly.




- Connect the 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 is heard.
3. After connecting make sure that the connection is secure by following method.
4. Pull the tube and the connector to make sure they are securely connected.
- Visually confirm that the two retainer tabs are connected to the connector.

INSPECTION AFTER INSTALLATION
- Use the following procedure to check for fuel leaks.
1. Turn ignition key ON (do not start engine) Then check connections for leaks by applying fuel pressure to fuel piping.
2. Start the engine and let it idle and make sure there are no fuel leaks at the fuel system connections.