Exploded View

1. Lock ring
2. Fuel level sensor unit 3. Seal packing

A. To fuel tank

: Always replace after every
disassembly

Removal and Installation

WARNING:
Read “General Precautions” when working on the fuel system. Refer to FL-45, "General Precautions".

REMOVAL

1. 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 10 (2-5/8 US gal, 2-1/4 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. Refer to FL-55, "Exploded View".

c. Insert hose into fuel tank through fuel filler hose to draw fuel from fuel tank.

2. Open fuel filler lid.

3. Open filler cap and release the pressure inside fuel tank.

4. Remove rear seat. Refer to SE-32, "Exploded View".

5. Remove inspection hole cover.

• Using a screwdriver, remove it by turning clips clockwise by 90 degrees.

6. Disconnect harness connector (1), fuel feed tube (4) and quick connector (3).

2 : Fuel level sensor unit : Vehicle front

• Hold the connector while pushing in tabs, and pull out the tube.

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.

7. Using lock ring wrench [SST: KV99104700 (Mot.1397)], remove lock ring.

CAUTION:
Rotate SST while pressing fuel level sensor unit as spring reaction force is applied from fuel tank inside to up ward.

8. Remove fuel level sensor unit.

2 : O-ring

CAUTION:
• Be careful not to bend the float arm (3) when removing.

• Handle them carefully without subjecting them to impacts such as dropping.

INSTALLATION

Note to the following, and install in the reverse order of removal.

Fuel Level Sensor Unit
1. Temporarily install the O-ring to the fuel level sensor unit.

2. Insert the fuel level sensor unit to the fuel tank, and then install the temporarily installed O-ring (Step 1) to the opening of the fuel tank.

3. Install fuel level sensor unit to fuel tank with alignment mark (B) on the upper surface facing the tree inscribed lines (A) on the tank side.

: Vehicle front

CAUTION:
• Never allow O-ring to drop.

• Never bend float arm during installing.

4. Install lock ring for fuel level sensor unit, fuel filter and fuel pump assembly with lock ring wrench [SST: KV993G0010 (Mot. 1397)] by turning clockwise.

CAUTION:
Install lock ring horizontally.

Quick Connector
Connect quick connector as follows: 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, check that the connection is secure by following method.

• Visually confirm that the two tabs are connected to the connector.

• Pull (A) the tube and the connector to check they are securely connected.

1 : Quick connector