Be sure to read -General Precautions- before working on the fuel system. Refer to Precautions in the General Information Section.
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) in the accompanying illustration.
NOTEFuel will be spilled when removing fuel pump assembly if fuel level is above the fuel pump assembly installation surface.
NOTEAs a guide, fuel level is at the level as shown (in the accompanying illustration) or below when approximately 3 1/8 gal of fuel is drained from a full fuel tank.
NOTEIn case fuel pump does not operate, perform the following procedure.
- Insert fuel tubing of less than 0.98 in. (25 mm) in diameter into fuel filler tube through fuel filler opening to drain fuel from fuel filler tube.
- Disconnect fuel filler hose from fuel filler tube.
- Insert fuel tubing into fuel tank through fuel filler hose to drain fuel from fuel tank.
- Open fuel door and unscrew the fuel filler cap to release the pressure inside the fuel tank.
- Release the fuel pressure from the fuel lines. Refer to Gasoline Fuel Injection System in the Fuel Systems Section.
- Disconnect battery negative terminal.
- Remove rear seat bottom. Refer to Seats in the Body Section
- Turn the three retainers (A) 90°in a clockwise direction and remove the fuel pump inspection hole cover.
Disconnect electrical connector and fuel feed hose quick connector.
Fuel feed hose.
Disconnect the quick connector using the following procedure:
NOTEThe tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.
NOTEDo not use any tools to remove the quick connector.
NOTEKeep resin tube away from heat. Be especially careful when welding near the resin tube.
NOTEPrevent acid liquid such as battery electrolyte, from getting on resin tube.
NOTEDo not bend or twist resin tube during installation and removal.
WARNINGTo keep the connecting portion clean, free of foreign materials and to avoid damage, cover them completely with plastic bags or something similar.
WARNINGDo not insert plug to prevent damage to O-ring in quick connector.
Hold the sides of the connector, push in tabs and pull out the tube.
- Fuel feed hose.
Remove the lock ring using Tool J-45722 as shown in the accompanying illustration.
Remove fuel level sensor unit, fuel filter and fuel pump assembly.
NOTEDo not bend float arm during removal.
NOTEDo not allow foreign materials to fall into fuel tank. Use a lint free cloth when handling components.
NOTEAvoid impacts such as dropping when handling components.
INSPECTION AFTER REMOVAL
Make sure that the fuel level sensor unit, fuel filter and fuel pump is free from defects and foreign materials.
Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
- Install O-ring to fuel tank without twisting.
Install fuel level sensor unit, fuel filter and fuel pump assembly as shown in the accompanying illustration.
- 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- sound is heard.
- After connecting, make sure that the connection is secure using the following procedure.
Inspection Hole Cover
- Before installing inspection hole cover, confirm that there are no fuel leaks. Refer to Fuel Tank in the Fuel Systems Section.
- Install inspection hole cover with the front mark facing front of vehicle.
Lock clips by turning counterclockwise.
- Install rear seat bottom. Refer to Seats in the Body Section
- Connect battery negative terminal.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
- 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.
- Start the engine and let it idle to check that there are no fuel leaks at the fuel system connections.