Removal
Warning: Make sure there is a fire extinguisher near the work area. Do not allow open flames near the work area. Work in a well-ventilated area.
1. Models with SR20DE engine: Relieve fuel pressure.
2. Open the fuel filler door.
3. Unscrew the filler cap and release the fuel vapor pressure in the tank.
4. Remove the second row seat cushions and backrests.
5. Remove the floor covering, then the inspection hole cover.
Using a screwdriver, turn the clamp 90° clockwise, then remove the cover.
6. Disconnect the electrical wiring connector and fuel hoses.
Remove the quick release couplings:
Squeeze the latches on the sides of the holder with your fingers and pull it up.
If the connector and tube on the transmitter side do not come off, pull it back and forth until it starts to move and remove it.
Attention:
Do not heat the rubber tube. Be especially careful when welding near the tube.
Do not allow the rubber tube to come into contact with corrosive liquids, such as battery electrolyte.
Do not twist or bend the tube during removal and installation.
Do not remove the holder from the tube side except when replacing the tube.
When replacing the tube, replace the holder with a new one.
Holder color:
- Fuel side: orange or green
- Fuel return side: white or grey
Wrap the connection in a bag to prevent contamination.
7. Remove the fuel level sensor, fuel filter and fuel pump assembly (models with SR engine) or fuel level sensor unit (models with YD engine).
Attention:
Do not bend the float lever during removal.
Do not drop parts or subject them to impact.
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
Make sure the fuel pump coarse filter is free of foreign particles (models with SR engine).
The hose connections of the sending unit should be directed towards the front of the vehicle. Align the pin and the hole for it on the fuel tank side.
Align the slots so that they are parallel to the slots on the fuel tank and install the bracket.
Tighten the holder mounting bolts evenly.
Caution: Use genuine mounting bolts.
Install the quick release couplings in the following order:
(1) Check the connection for damage and contamination.
(2) Align the connection with the center of the tube axis and insert the tube without tilting it so that the connection clicks into place with a distinctive sound.
(3) After installation, make sure the connection is securely fixed.
Make sure the two holder latches are locked into place.
Pull on the tube and connection to ensure they are tight.
Examination
Start the engine, increase the speed and check for fuel leaks.