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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYFL-7
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Remove the quick connector as follows:
• Hold the sides of the connector, push in tabs (B) and pull (A)
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:
• Quick connector (1) can be disconnected when the tabs (F) are depressed completely. Do not twist it more than
necessary.
• Do not use any tools to disconnected quick connector.
• Keep resin tube (C) 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.
• Do not bend or twist resin tube during installation and dis- connection.
• Do not remove the remaining retainer (2) on hard tube (or
the equivalent) (A) except when resin tube or retainer is
replaced.
• When resin tube or hard tube (or the equivalent) is
replaced, also replace retainer with new one.
• To keep the connecting portio n clean and to avoid dam-
age and foreign materials, cover them completely with
plastic bags (A) or something similar.
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(B) : Connection (cross-section)
(D) : To under floor fuel line
(E) : To fuel tank
(G) : Disconnection
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FL -8
< REMOVAL AND INSTALLATION >
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
8. Remove lock ring for fuel level sensor unit, fuel filter and fuel
pump assembly using Tool (A) by turning counterclockwise.
9. Remove fuel level sensor unit, fuel filter and fuel pump assembly. CAUTION:
• Do not bend float arm during removal.
• Do not allow contaminants to fa ll inside of the fuel tank.
• Do not cause impacts such by dro pping when handling components.
INSTALLATION
Installation is in the reverse order of removal.
• Install the fuel level sensor, fuel filter, and fuel pump assembly with
the fuel feed tube (C) facing the front of the vehicle as shown. Use
a new O-ring.
CAUTION:
Do not reuse O-ring.
• Connect the quick connector as follows:
- Check the connection for damage or any foreign materials.
- Align the connector with the tube, then insert the connector straight into the tube until a click is heard.
• After the tube is connected, make sure the connection is secure by performing the following checks:
- Pull (A) the tube and the connector to make sure they are securely
connected. Tool number (A) : KV10119900 ( — ) (Shown)
: KV101207S0 ( — )
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: Front
(A) : EVAP tube
(B) : Harness connector
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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYFL-9
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- Visually confirm that the two retainer tabs (F) are connected to the
quick connector (1).
• Perform inspection after installation. Refer to FL-9, "
Inspection".
InspectionINFOID:0000000012432111
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch “ON” (with engine stopped), then check fuel system connections for leaks by applying
fuel pressure to fuel piping.
2. Start engine and let it idle and check there are no fuel leaks at the fuel system connections.
(B) : Connection (cross-section)
(C) : Resin tube
(D) : To under floor fuel line
(E) : To fuel tank
(G) : Disconnection
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FL-10
< REMOVAL AND INSTALLATION >
FUEL TANK
FUEL TANK
Exploded ViewINFOID:0000000012432112
Removal and InstallationINFOID:0000000012432113
WARNING:
Read “General Precautions” when working on the fuel system. Refer to FL-2, "
General Precaution".
NOTE:
When removing components such as hoses, tubes/lines, etc. , cap or plug openings to prevent fluid from spill-
ing.
REMOVAL
1. Check the fuel level with the vehicle on a level surface. If the fuel gauge indicates more than the level as shown (1/2 full), drain
the fuel from the fuel tank until the fuel gauge indicates a level at
or below as shown (1/2 full).
• In case the fuel pump does not operate, use the following pro-cedure.
a. Disconnect the fuel filler hose from the fuel filler tube.
b. Insert fuel tubing of less than 20 mm (0.79 in) diameter into the fuel filler tube through the fuel f iller opening to drain fuel from the
fuel filler tube.
• As a guide, if the fuel tank is full the fuel level reaches or is less than the level on the fuel gauge as shown, when approxi-
mately 20-1/2 (5-3/8 US gal, 4-1/2 Imp gal) of fuel is drained from a full fuel tank.
2. Release the fuel pressure from the fuel lines. Refer to EC-137, "
Work Procedure".
1. Fuel tank2. Fuel tank mounting band (RH) 3. Fuel tank mounting band (LH)
4. Clamp 5. Fuel filler hose 6. Fuel filler tube
7. Grommet 8. Fuel filler cap 9. Clamp
10. Vent hose 11. EVAP tube Front
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FUEL TANKFL-11
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3. Open fuel filler lid.
4. Open fuel filler cap and release
the pressure inside fuel tank.
5. Remove the rear seat cushion. Refer to SE-26, "
SEAT CUSHION : Removal and Installation".
6. Remove the inspection hole cover. NOTE:
Inspection hole cover is held by an adhesive.
7. Disconnect the harness connector (B), fuel feed tube (C) and
EVAP tube (A).
Remove the quick connector as follows:
• Hold the sides of the connector, push in tabs (B) and pull (A) 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:
• Quick connector (1) can be disconnected when the tabs (F) are depressed completely. Do not twist it more than
necessary.
• Do not use any tools to disconnected quick connector.
• Keep resin tube (C) 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.
• Do not bend or twist resin tube during installation and dis- connection.
• Do not remove the remaining retainer (2) on hard tube (or the equivalent) (A) except when resin tube or retainer is
replaced.
• When resin tube or hard tube (or the equivalent) is replaced, also replace retainer with new one.
: Front
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(B) : Connection (cross-section)
(D) : To under floor fuel line
(E) : To fuel tank
(G) : Disconnection
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FL-12
< REMOVAL AND INSTALLATION >
FUEL TANK
• To keep the connecting portion clean and to avoid dam-
age and foreign materials, cover them completely with
plastic bags (A) or something similar.
8. Remove center muffler. Refer to EX-5, "
Exploded View".
9. Remove nut (A) and remove center floor insulators.
10. Disconnect the rear park brake cable brackets (LH). Refer to PB-6, "
Exploded View".
11. Disconnect fuel filler hose (2) at fuel filler tube (1) side.
12. Disconnect vent hose (3) from fuel tank side.
13. Disconnect EVAP vent line. Refer to FL-14, "
Exploded View".
14. Support the center part of fuel tank (1) using a suitable jack (A).
15. Remove fuel tank mounting bands (LH/RH).
16. Lower suitable jack carefully to remove fuel tank while holding it by hand. CAUTION:
Fuel tank may be in an unstable condition because of the shape of fuel tank bottom. Be sure to
hold fuel tank securely.
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FUEL TANKFL-13
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17. If replacing the fuel tank, remove the fuel level sensor unit, fuel filter and fuel pump assembly to transfer to
the new fuel tank.
CAUTION:
Do not reuse O-ring.
INSTALLATION
Installation is in the reverse order of removal.
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.
• Install fuel filler hose to fuel t ank, paying attention to install mark.
EVAP Hose
1. Check connections for damage or foreign material.
2. Align the matching side connection part with the center of shaft, and insert connector straight until a "click"
sound is heard.
InspectionINFOID:0000000012432114
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch “ON” (with engine stopped), then check fuel system connections for leaks by applying
fuel pressure to fuel piping.
2. Start engine and let it idle and check there are no fuel leaks at the fuel system connections.
Fuel filler hose : 35 mm (1.38 in)
Vent hose : 25 mm (0.98 in)
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FL-14
< REMOVAL AND INSTALLATION >
EVAP CANISTER
EVAP CANISTER
Exploded ViewINFOID:0000000012432115
Removal and InstallationINFOID:0000000012432116
NOTE:
The EVAP canister vent control valve and EVAP canister system pressure sensor can be removed without
removing the EVAP canister.
REMOVAL
1. Release pawls and remove EVAP canister protector cover.
2. Disconnect the harness connectors from the EVAP control system pressure sensor and the EVAP canis- ter vent control valve.
3. Disconnect the EVAP canister purge hose, the EVAP vent line, and the EVAP canister vent control valve
hose.
4. Remove the EVAP canister bolt.
5. Remove the EVAP canister from the vehicle.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Do not reuse O-rings.
1. EVAP control system pressure sensor 2. O-ring 3. EVAP canister protector
4. Hose clamp 5. EVAP canister purge hose6. EVAP vent line
7. EVAP canister vent control valve hose 8. EVAP canister vent control valve 9. O-ring
10. EVAP canister PawlFront
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