Front Wheel Drive

Preremoval Operation
- Fuel Draining
- Reduce the Inner Pressure of Fuel Line and Hose

Post-installation Operation
- Fuel Refilling
- Checking for Fuel Leaks





Removal steps
1. Fuel tank
2. Vapor hose
3. High-pressure fuel hose
4. Return hose
5. Fuel pump assembly
6. Fuel gauge unit
7. Fuel cut-off valve assembly
8. Vapor hose
9. Fuel tank filler tube cap
10. Filler hose
11. Vapor hose
12. Fuel tank filler tube protector
13. Reinforcement
14. Fuel tank filler tube assembly
15. Packing

NOTE: When replacing the fuel pump assembly or the fuel gauge unit only, it is possible to work from the service holes underneath the rear seat cushion without having to remove the fuel tank.





INSTALLATION SERVICE POINT
A. CAP INSTALLATION
Use the special tool to install the cap.





INSPECTION
FUEL TANK FILLER TUBE ASSEMBLY CHECK

(1) Connect a clean rubber hose to the port A of the fuel tank filler tube assembly.





(2) Blow air into the hose. Check that the air flows out of the port B.
(3) Use a screwdriver or similar tool to close the valve. Blow air into the hose in this condition. Check that the air does not flow out of the port B.





FUEL CUT OFF VALVE CHECK
If the sound of the float valve moving (knocking sound) can be heard when the valve assembly is gently shaken up and down, then the valve is okay.
FUEL GAUGE UNIT CHECK
Refer to Combination Meter.





FUEL GAUGE UNIT AND PUMP ASSEMBLY REPLACEMENT

(1) Remove the rear seat cushion. (Refer to Seat.)
(2) Remove the protector.





(3) Disconnect the hoses and connectors to remove the fuel pump assembly or fuel gauge unit.
(4) Align the packing positioning projections with the holes in the fuel pump assembly.





(7) After applying soapy water to the outside thread of the fuel tank, install the cap and use the special tool to tighten it to the specified torque.





Caution: The packing should be installed as shown in the image.

(8) Check for leaks from the installation section of the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly by the following procedure.
1. Apply soapy water to the circumference of the cap.
2. Choke the vapor hose and main hose, apply an internal pressure of 10 kPa (1.5 psi) or less from the return hose and check to be sure that no bubbles form in the soapy water.