Disassembly and Assembly

Disassembly and Assembly

CAUTION: Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.

DISASSEMBLY
1. Separate main fuel level sensor unit as follows:
a. Fit a used O-ring into space between main fuel level sensor unit and fuel filter. Undo catches and separate main fuel level sensor unit and fuel filter.
- For reference when reassembling, put a mating mark on outer edges of main fuel level sensor unit and fuel filter with some means which cannot be erased by fuel.




b. Insert flat-blade screwdriver to the gap between the fuel filter and main fuel level sensor unit to separate them.

CAUTION:
- Put cloth or similar one on the edge of flat-blade screwdriver not to damage the inserted portion.
- Separate main fuel level sensor unit by pulling it straight.
If lateral force is applied, inner resin tube (between main fuel level sensor unit and fuel filter) may break.




2. Disconnect the harness connector from fuel pump side.




3. Separate bracket and fuel pump from fuel filter.
- Using flat-blade screwdriver, remove the snap fit portion of bracket in the order of (1), (2), (3) and (4) as shown in the figure.
- For reference when reassembling, put a mating mark on outer edges of fuel filter and bracket with some means which cannot be erased by fuel.

4. Remove pressure regulator from fuel filter as follows:
a. Open and remove the clip.
b. Pull pressure regulator straight out during removal.

CAUTION:
- Handle fuel tube carefully and avoid damaging it.
- Avoid impacts such as falling during removal.
- Do not disassemble or adjust.

ASSEMBLY
Note to the following, and assemble in the reverse order of disassembly.

Fuel Filter and Fuel Pump
- Install fuel filter and fuel pump with the tabs aligned, make sure a click sound of secure engagement is heard.
- Securely connect harness connector of fuel pump.

Pressure Regulator
Install pressure regulator as follows:
1. Install O-ring.

CAUTION:
- Do not reuse O-ring. Replace it with a new one.
- Handle O-ring with bare hands. Do not wear gloves.
- Visually check O-ring, mounting parts and mating parts for foreign materials and flaws.
- Before installing, lubricate new engine oil.
- To avoid damage, do not apply an excessive force (pulling or stretching).




2. Insert the clip to the groove of the regulator.

CAUTION: Do not reuse clip. Replace it with a new one.

3. With the clip installed, insert pressure regulator straight by matching the fuel filter protrusion and the clip notch.
4. Make sure that the fuel filter protrusion and clip notch are securely engaged.