Removal And Installation
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
AWD : Removal and Installation
REMOVAL
Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
WARNING:
Read "General Precautions" before working on the fuel system. General Precautions.
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. Exploded View.
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 cushion. 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 ling wrench (A) [SST: KV99110600 (J-46214)] by 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.
10. Separate fuel tube as per the following steps to remove fuel level sensor unit, fuel filter and fuel pump assembly.
- Pinch quick connector (A) square-part with your fingers, and pull out the quick connector by hand.
- If quick connector and tube on sender unit are stuck, push several times until they move, and pull out.
NOTE:
When separating the fuel tube, tie a gasoline-resistance rope to the tip of the fuel tube and leave the rope on the fuel tank side to easily pull the fuel tube for installation.
- Disconnect harness connector (B).
Sub Fuel Level Sensor Assembly
1. Remove fuel level sensor unit, fuel filter and fuel pump assembly.
2. Remove lock ring for sub fuel level sensor assembly with lock ling wrench (A) [SST: KV99110600 (J-46214)] by turning counter clockwise.
3. Remove sub fuel level sensor assembly (1).
CAUTION:
- Never disassemble a fuel tube (2) from sub fuel sensor assembly.
- 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.
NOTE:
Tie a gasoline-resistance rope to a tip of the tube. Draw and leave the rope to the fuel tank side so that the rope can be the
guide for installation.
INSTALLATION
Note the following, and install in the reverse order of removal.
Sub Fuel Level Sensor Assembly
1. Install O-ring to fuel tank without any twist.
2. Using the rope left on the fuel tank side at removal, run the fuel tube inside the fuel tank to install the sub fuel level sensor assembly to the fuel tank.
CAUTION:
- Never bend float arm during installation.
- To install, fuel tube (1) must run to the front ( Arrow ) of the vehicle to avoid the interference with the float arm (2), as shown in the figure.
Arrow Indicates : Vehicle front
3. Install sub fuel level sensor assembly (1) with its matching mark
(A) aligned with fuel tank matching mark (B) as shown in the figure.
NOTE:
- Figure shows fuel level sensor unit, fuel filter and fuel pump assembly side of fuel tank.
- For sub fuel level sensor assembly matching mark is located on the fuel tank of the vehicle rear side.
4. Install lock ring for sub fuel level sensor assembly with lock ling wrench (A) [SST: KV99110600 (J-46214)] by turning clockwise.
Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
1. Temporarily install the O-ring to the fuel level sensor unit, fuel filter and fuel pump assembly.
2. Connect the fuel tube as per the following steps.
- Insert the quick connector (A) straight to the fuel level sensor unit, fuel filter and fuel pump assembly.
- Judge a good fit from connecting sound and tactile feedback.
- Pull the fuel tube by hand to check a secure fit.
3. Connect harness connector (B).
4. Insert the fuel level sensor unit, fuel filter and fuel pump assembly to the fuel tank.
CAUTION:
- Never bend float arm during installation.
- To install, fuel tube (1) must run to the front (White Arrow) of the vehicle to avoid the interference with the float arm (2), as shown in the figure.
- Through the clearance of the mounting part of the fuel level sensor unit and the fuel filter and fuel pump assembly, visually check that the fuel tube is placed on the vehicle front side of them.
Arrow Indicates : Vehicle front
5. 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.
6. Install lock ring for fuel level sensor unit, fuel filter and fuel pump assembly with lock ling wrench (A) [SST: KV99110600 (J-46214)] by turning clockwise.
7. 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 secured with following procedures.
- Visually confirm that the two tabs are connected to the connector.
- Pull (A) the tube and the connector to check that they are securely connected.
8. Connect harness connector.
Inspection Hole Cover
- Before installing inspection hole cover, check that the connecting part has no fuel leakage. Inspection Exploded View SEE AWD : Removal and Installation, "2WD : Inspection".
1. Install inspection hole covers with the front mark (arrow) facing front of vehicle.