FL-6
< SERVICE INFORMATION >
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
6. Disconnect electrical connector (A) and fuel feed hose quick
connector (B).
• Fuel feed hose (1)
•⇐ : Vehicle front
• Disconnect the quick connector using the following procedure.
- Hold the sides of the connector, push in tabs and pull out the
tube.
- If quick connector and tube on fuel pump assembly are stuck,
push and pull several times until they move. 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 resin tube away from heat. Be especially careful
when welding near the resin tube.
• Prevent acid liquid such as battery electrolyte, from get-
ting on resin tube.
• Do not bend or twist resin tube during installation and removal.
• To keep the connecting portion clean, free of foreign
materials and to avoid damage, cover them completely
with plastic bags or something similar.
• Do not insert plug to prevent damage to O-ring in quick
connector.
7. Remove the lock ring using Tool as shown.
8. Remove fuel level sensor unit, fuel filter and fuel pump assembly (1).
CAUTION:
• Do not bend float arm during removal.
• Do not allow foreign materials to fall into fuel tank. Use a lint free cloth when handling compo-
nents.
• Avoid impacts such as dropping when handling components.
INSPECTION AFTER REMOVAL
WBIA0782E
SFE562A
PBIC0163E
Tool number : KV991J0090 (J-46214)
WBIA0284E
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-7
< SERVICE INFORMATION >
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Make sure that the fuel level sensor unit, fuel filter and fuel pump is free from defects and foreign materials.
INSTALLATION
Installation is in the reverse order of removal.
Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
1. Install O-ring to fuel tank without twisting.
2. Install fuel level sensor unit with aligning mating marks (A) on
fuel tank and fuel level sensor unit as shown.
•⇐: Front
• Turn the lock ring (1) until the lock ring is fully rotated into the
fuel tank lock tabs (A) as shown.
Quick Connector
Connect fuel feed tube quick connector using the following procedure.
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, make sure that the connection is secure using the following procedure.
• Visually confirm that the two retainer tabs are secured to the connector.
• Pull the tube and the connector to make sure they are securely
connected.
4. Connect electrical harness connector.
Inspection Hole Cover
• Before installing inspection hole cover, confirm that there are no fuel leaks. Refer to "INSPECTION AFTER
INSTALLATION" .
1. Install inspection hole cover with the front mark (arrow) facing front of vehicle.
2. Lock clips by turning counterclockwise.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
PBIC4732E
WBIA0783E
PBIC1653E
FUEL TANK
FL-9
< SERVICE INFORMATION >
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FUEL TANK
ComponentINFOID:0000000001703101
Removal and InstallationINFOID:0000000001703102
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-4, "
General Pre-
caution" .
1. Drain fuel from fuel tank if necessary. Refer to FL-5, "
Removal and Installation" .
CAUTION:
• Because fuel tank becomes unstable when installing/removing, fuel should be drained if the
level exceeds specification FL-5, "
Removal and Installation" .
• Situate vehicle on a flat and solid surface.
2. Open fuel door and unscrew the fuel filler cap to release the pressure inside the fuel tank.
3. Release the fuel pressure from the fuel lines. Refer to EC-78, "
Fuel Pressure Check" .
4. Remove rear seat bottom. Refer to SE-14
.
5. Turn the three retainers 90° in a clockwise direction and remove the fuel pump inspection hole cover.
1. Lock ring 2. Fuel pump 3. O-ring
4. Fuel tank 5. Fuel tank band (LH) 6. Fuel tank band (RH)
7. EVAP hose 8. Hose clamp 9. Fuel filler hose
10. Hose clamp 11. Fuel filler pipe shield 12. Fuel filler tube
13. Grommet 14. Fuel filler cap⇐Front of vehicle
WCIA0591E
FL-10
< SERVICE INFORMATION >
FUEL TANK
Disconnect electrical connector (A) and fuel feed hose quick connec-
tor (B).
• Fuel feed hose (1)
•⇐ : Vehicle front
• Disconnect the quick connector using the following procedure.
- Hold the sides of the connector, push in tabs and pull out the tube.
- If quick connector and tube on fuel pump assembly are stuck, push
and pull several times until they move. 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 resin tube away from heat. Be especially careful when
welding near the resin tube.
• Prevent acid liquid such as battery electrolyte, from getting
on resin tube.
• Do not bend or twist resin tube during installation and
removal.
• To keep the connecting portion clean, free of foreign materi-
als and to avoid damage, cover them completely with plastic
bags or something similar.
• Do not insert plug to prevent damage to O-ring in quick con-
nector.
6. Remove center exhaust tube. Refer to EX-4
.
7. Remove exhaust heat shields.
8. Disconnect parking brake cables (1) from the lower surface of
fuel tank and axle and position the parking brake cables (1) out
of the way.
WBIA0782E
SFE562A
PBIC0163E
PBIC3786E
FUEL TANK
FL-11
< SERVICE INFORMATION >
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9. Remove brake tube protector (1) from rear axle (2).
10. Loosen fuel filler hose clamp (3) and remove fuel filler hose (1)
from fuel tank (2).
CAUTION:
Do not remove fuel filler hose (1) from fuel filler tube. Do not
allow contact with the suspension during installation. When
removing fuel filler hose (1) at the fuel filler tube, mark com-
ponents for alignment.
11. Remove vent hose (1) and EVAP hose (2) at rear of fuel tank.
• Disconnect vent hose and EVAP hose quick connectors using
the following procedures.
a. Pinch retaining tabs (A) of vent hose quick connector and
remove vent hose (1).
b. Slide sleeve (B) of EVAP hose quick connector and remove
EVAP hose (2).
• If hoses are stuck, push and pull several times until they move
freely, and disconnect.
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, from getting on the resin tube.
• Do not bend or twist the tube during installation and removal.
• Do not insert plug that may cause damage to O-ring in quick connector.
• To keep the connecting portion clean and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
WBIA0764E
WBIA0765E
WBIA0766E
PBIC0163E
FL-12
< SERVICE INFORMATION >
FUEL TANK
12. Support center of fuel tank (1) with transmission jack (A).
CAUTION:
Securely support the fuel tank with a suitable tool (B).
13. Remove fuel tank bands (RH and LH).
14. Lower transmission jack carefully to remove fuel tank while sup-
porting it by hand.
CAUTION:
Fuel tank may be in an unstable position because of the
shape of fuel tank bottom. Be sure to support tank securely.
INSTALLATION
Installation is in the reverse order of removal.
EVAP Canister
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, make sure that the connection is secure.
• Pull the tube and the connector to make sure they are securely connected.
Fuel Tank Bands
Install the fuel tank bands in the proper position by referring to the identification stamp mark “R” and “L” on the
end
1. While supporting the fuel tank, install bolts 1, 3 and 4 to support
the tank, but do not fully tighten.
• ⇐ : Front
2. Install bolt 2 while positioning the fuel tank toward the front of
the vehicle. Tighten bolt 2 to specified torque.
3. Tighten bolts 1, 3 and 4 to specified torque.
Fuel Filler Hose
• Insert fuel filler hose to the length below.
• Be sure hose clamp is not placed on swelled area of fuel filler tube.
EVAP Hose
PBIC3792E
WBIA0847E
Fuel filler install length : 35mm (1.38 in)
LT-46
< SERVICE INFORMATION >
FRONT FOG LAMP
1. Check continuity between front fog lamp harness connector and
ground.
OK or NG
OK >> Replace IPDM E/R. Refer to PG-26, "Removal and
Installation of IPDM E/R" .
NG >> Repair harness or connector.
Aiming AdjustmentINFOID:0000000001704409
The front fog lamp is a semi-sealed beam type which uses a replaceable halogen bulb. Before performing
aiming adjustment, make sure of the following.
• Keep all tires inflated to correct pressure.
• Place vehicle on level surface.
• Set that there is no-load in vehicle other than the driver (or equivalent weight placed in driver’s position).
Coolant, engine oil filled up to correct level and full fuel tank, spare tire, jack and tools are properly stowed.
Adjust aiming in the vertical direction by turning the adjusting screw (A).
1. Set the distance (C) between the screen and the center of front
fog lamp lens (E) as shown.
2. Turn front fog lamps (1) to ON.
3. Adjust front fog lamps using adjusting screw so that the top edge
of the high intensity zone (A) is as shown.
NOTE:
When performing adjustment, if necessary, cover the headlamps
and opposite front fog lamp.
Front fog lamp connector Terminal
Ground Continuity
RH E28
2Yes
LH E27
PKIA6277E
PKIC1070E
Aiming distance from center of fog lamp to screen (C) 25,000 mm (984.3 in)
Foglamp beam width (D) 870 mm (34.3 in)
Horizontal distance from ground to bottom edge of high
intensity zone (B)220 mm (8.7 in)
Horizontal distance from bottom edge to top edge of
high intensity zone (A)21.75 mm (0.9 in)
LKIA0931E
MA-14
< SERVICE INFORMATION >
ENGINE MAINTENANCE
1. Install reservoir tank if removed. Refer to CO-11 .
2. Install radiator drain plug.
•If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-76
.
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring. Refer to CO-11, "
Component" .
3. Fill radiator and reservoir tank with water and reinstall radiator cap.
4. Run engine and warm it up to normal operating temperature.
5. Rev engine two or three times under no-load.
6. Stop engine and wait until it cools down.
7. Drain water from the cooling system. Refer to "DRAINING ENGINE COOLANT" .
8. Repeat steps 1 through 7 until clear water begins to drain from radiator.
InspectionINFOID:0000000001704732
LEVEL CHECK
• Check if the reservoir tank engine coolant level is within the “MIN”
to “MAX” range when engine is cool.
• Adjust the engine coolant level as necessary.
CHECKING COOLING SYSTEM FOR LEAKS
To check for leaks, apply pressure to the cooling system using Tool.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
Checking Fuel LineINFOID:0000000001704733
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
Changing Air Cleaner FilterINFOID:0000000001704734
REMOVAL
SMA412B
Tool number : EG17650301 (J-33984-A)
Testing pressure
: 157 kPa (1.6 kg/cm
2 , 23 psi)
WBIA0568E
SMA803A