FL-1
ENGINE
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SECTION FL
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CONTENTS
FUEL SYSTEM
SERVICE INFORMATION ............................2
PRECAUTIONS ...................................................2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................
2
PREPARATION ...................................................3
Special Service Tool .................................................3
Commercial Service Tool ..........................................3
FUEL SYSTEM ....................................................4
Checking Fuel Line ...................................................4
General Precaution ...................................................4
FUEL LEVEL SENSOR UNIT, FUEL FILTER
AND FUEL PUMP ASSEMBLY .........................
5
Component ...............................................................5
Removal and Installation ..........................................5
FUEL TANK .......................................................9
Component ...............................................................9
Removal and Installation ..........................................9
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................
14
Standard and Limit ..................................................14
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-5
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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
ComponentINFOID:0000000001703099
Removal and InstallationINFOID:0000000001703100
REMOVAL
WARNING:
Be sure to read “General Precautions” before working on the fuel system. Refer to FL-4, "
General Pre-
caution" .
1. Check fuel level with the vehicle on a level surface. If the fuel
gauge indicates more than the level as shown (7/8 full), drain
fuel from the fuel tank until the fuel gauge indicates level as
shown (7/8 full).
NOTE:
Fuel will be spilled when removing fuel pump assembly if fuel
level is above the fuel pump assembly installation surface.
• As a guide, fuel level is at the level as shown or below when
approximately 12 (3 1/8 US gal, 2 5/8 Imp gal) of fuel is
drained from a full fuel tank.
• In case fuel pump does not operate, perform the following pro-
cedure.
a. Insert fuel tubing of less than 25 mm (0.98 in) in diameter into fuel filler tube through fuel filler opening to
drain fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-9
.
c. Insert fuel tubing into fuel tank through fuel filler hose to drain fuel from fuel tank.
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 four retainers 90° in a clockwise direction and remove the fuel pump inspection hole cover.
1. Lock ring 2. Fuel level sensor unit, fuel filter and fuel pump assembly 3. O-ring
4. Fuel tank
WCIA0590E
KBIA3505J
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
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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
FL-8
< SERVICE INFORMATION >
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
1. Turn ignition switch “ON” (without starting the engine), to check the connections for fuel leaks with the
electric fuel pump applying pressure to the fuel piping.
2. Start the engine and let it idle to check that there are no fuel leaks at the fuel system connections.
FRONT SUSPENSION ASSEMBLY
FSU-7
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• This may result in an ERROR.
2. Some newer alignment machines are equipped with an optional “Rolling Compensation” method to “com-
pensate” the sensors (alignment targets or head units). Do NOT use this “Rolling Compensation”
method.
• Use the “Jacking Compensation” method. After installing the alignment targets or head units, raise the
vehicle and rotate the wheels 1/2 turn both ways.
• See Instructions in the alignment machine you are using for more information.
CAMBER, CASTER AND KINGPIN INCLINATION ANGLES INSPECTION
• Camber, caster, kingpin inclination angles cannot be adjusted.
• Before inspection, mount front wheels onto turning radius gauge. Mount rear wheels onto a stand that has
same height so vehicle will remain horizontal.
Using a CCK Gauge
Install the CCK gauge attachment [SST: KV991040S0] with the following procedure on wheel, then measure
wheel alignment.
1. Remove three wheel nuts, and install the guide bolts to hub bolt.
2. Screw the adapter into the plate until it contacts the plate tightly.
3. Screw the center plate into the plate.
4. Insert the plate assembly on the guide bolt. Put the spring in,
and then evenly screw the three guide bolt nuts. When fastening
the guide nuts, do not completely compress the spring.
5. Place the dent of alignment gauge onto the projection of the
center plate and tightly contact them to measure.
CAUTION:
• If camber, caster, or kingpin inclination angle is outside
the specification, check front suspension parts for wear
and damage. Replace suspect parts if a malfunction is
detected.
• Kingpin inclination angle is reference value, no inspection
is required.
TOE-IN INSPECTION
Measure toe-in using the following procedure.
WARNING:
• Always perform the following procedure on a flat surface.
• Make sure that no person is in front of vehicle before pushing it.
1. Bounce the front of vehicle up and down to stabilize the vehicle height (posture).
2. Push vehicle straight ahead about 5 m (16 ft).Tool number : KV991040S0 ( — )
SEIA0240E
Camber, caster, kingpin inclination angles:
Refer to FSU-16, "
Wheel Alignment (Unladen*)" .
SEIA0241E
FSU-10
< SERVICE INFORMATION >
FRONT SUSPENSION ASSEMBLY
Removal and Installation
INFOID:0000000001703724
REMOVAL
1. Separate intermediate shaft from steering gear pinion shaft. Refer to PS-9, "Removal and Installation".
2. Remove front tires from vehicle using a power tool.
3. Remove wheel sensor from steering knuckle. Refer to BRC-32
.
CAUTION:
Do not pull on wheel sensor harness.
4. Remove the nut on the upper side of stabilizer connecting rod
(1) with a power tool, and then remove stabilizer connecting rod
(1) from strut assembly.
5. Loosen steering outer socket (1) nut.
6. Remove steering outer socket (1) from steering knuckle (2) so
as not to damage ball joint boot (3) using Tool.
CAUTION:
Temporarily tighten the nut to prevent damage to threads
and to prevent the Tool from suddenly coming off.
7. Remove rear torque rod. Refer to EM-72, "
Component" .
8. Remove transverse link ball joint nut and bolt. Then, remove transverse link from steering knuckle.
9. Set jack under front suspension member.
10. Remove upper side bolts of upper link.
11. Remove the bolts of member stay, and then remove member stay from vehicle.
12. Gradually lower a jack to remove front suspension assembly.
INSTALLATION
Installation is in the reverse order of removal.
• For tightening torque, refer to FSU-9, "
Component" .
• Perform final tightening of each of parts (rubber bushing), under unladen conditions, which were removed
when removing front suspension assembly. Check wheel alignment. Refer to RSU-2, "
Precaution for Sup-
plemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"" .
• Check wheel sensor harness for proper connection. Refer to BRC-32
.
13. Upper link (right) 14. Front suspension member 15. Member stay
16. Cap⇐:Front
Refer to GI-7
for the symbols.
SGIA1297E
Tool number : HT72520000 (J-25730-A)
SGIA1298E
COIL SPRING AND STRUT
FSU-11
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COIL SPRING AND STRUT
Removal and InstallationINFOID:0000000001703725
REMOVAL
1. Remove cowl top panel. Refer to EI-21 .
2. Remove front tires using power tool.
3. Remove harness of wheel sensor from strut assembly. Refer to BRC-32
.
CAUTION:
Do not pull on wheel sensor harness.
4. Remove brake hose lock plate. Refer to BR-10
.
5. Remove the nut on the upper side of stabilizer connecting rod using power tool, and then remove stabi-
lizer connecting rod from strut assembly.
6. Remove nuts and bolts, and then remove steering knuckle from
strut assembly. Refer to FSU-9, "
Component" .
7. Remove the strut mounting insulator bolts, then remove strut
assembly.
INSTALLATION
Installation is in the reverse order of removal.
• For tightening torque, refer to FSU-9, "
Component" .
• Perform final tightening of bolts and nuts at the strut assembly lower side (rubber bushing) under unladen
conditions with tires on level ground. Check wheel alignment. Refer to RSU-2, "
Precaution for Supplemental
Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"" .
• Check wheel sensor harness for proper connection. Refer to BRC-32
.
• Attach strut mounting insulator as shown.
Disassembly and AssemblyINFOID:0000000001703726
DISASSEMBLY
CAUTION:
Do not damage strut piston rod when removing components from strut assembly.
WEIA0179E
MEIA0014E