Removal And Installation

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

Removal and Installation


WARNING:
Read "General Precautions" when working on the fuel system. General Precautions.

REMOVAL

1.Check fuel level on a level ground. If the fuel level is 7/8 of the fuel tank (full or nearly full), draw appropriate amount of fuel from the fuel tank.
Guideline:Draw approximately 20 liters (5-1/4 US gal) from a full-tank condition.
- In the event of malfunction in fuel pump, insert a hose measuring 20mm (0.79 in) in diameter into the filler opening to draw approximately 20 liters (5-1/4 US gal) fuel.
2.Release the fuel pressure from the fuel lines. Testing and Inspection (VQ-37VHR) or (VK-56VD).
3.Open fuel filler lid.
4.Open filler cap and release the pressure inside fuel tank.
5.Remove rear seat cushion. Exploded View.
6.Peel off floor carpet.





7.Remove mounting nuts (A), and then inspection hole cover.





Right side: Main fuel level sensor unit, fuel filter,


and fuel pump assembly
Left side: Sub fuel level sensor unit





8.Disconnect harness connector (3) and fuel feed tube (2).





NOTE:
- Fuel does not return to the fuel tank.
- The sub fuel level sensor unit includes a harness connector only.
- Figure shows main fuel level sensor unit, fuel filter and fuel pump assembly side of fuel tank.





- Hold the sides of connector, push in tabs and pull out fuel feed tube.





- If quick connector sticks to tube of main fuel level sensor unit, push and pull quick connector several times until they start to move.Then disconnect them by pulling.

CAUTION:





- Quick connector (1) can be disconnected when the tabs (F) are completely depressed. Never twist it more than necessary.





- Never 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.
- Never bend or twist resin tube during installation and disconnection.
- Never 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.
Retainer color: Green





- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags (A) or something similar.
9.Remove main fuel level sensor unit, fuel filter and fuel pump assembly, and sub fuel level sensor unit as follows:

CAUTION:
- Never bend float arm during removal.
- Avoid impacts such as falling when handling components.
a.Removal of main fuel level sensor unit, fuel filter and fuel pump assembly:
i.Remove retainer.
ii.Raise main fuel level sensor unit, fuel filter and fuel pump assembly, and disconnect quick connector as follows:





- Push in tabs (1) and pull out fuel tube (2).
b.Removal of sub fuel level sensor unit:
i.Remove retainer.
ii.Raise and release sub fuel level sensor unit to remove.

INSTALLATION

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





- When installing fuel hose connector (1), refer to "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.





- Pull the tube and the connector to check they are securely connected.





- Visually confirm that the two retainer tabs are connected to the connector.