Section04ENGINE
Subsection 08 (FUEL TANK AND FUEL PUMP)
FLOAT-TYPE FUEL LEVEL GAUGE
To remove gauge no. 4 from fuel tank, pull gauge
out of its grommet then remove grommet.
For reinstallation, proceed as follows:
– Install grommet halfway on gauge.
– Insert grommet in fuel tank until it bottoms.
– Firmly push gauge in grommet until it bottoms
andsothatitsredlinealignswiththelineon
the fuel tank.
1
A33C2XA
1. Align red line with line on tank
ELECTRIC FUEL LEVEL SENSOR
Inspection
All Models except SDI
Visually inspect the condition of connectors and
wiring throughout the circuit. Connections must
be clean and tight, and wiring free of damage. Re-
pair as necessary. Use silicone dielectric grease
to prevent corrosion at the connectors. Operate
theenginetoseeiftheproblemhasbeencor-
rected.
SDI Models
Fuel level sensor is integrated to the fuel pump.
Refer to COMPONENT INSPECTION AND AD-
JUSTMENT.
Fuse Replacement
Some Models
A 0.25 ampere fuse protects fuel level sensor cir-
cuitry. Remove seat to gain access.
SDI Models
A 0.5 amp. fuse protects fuel level sensor circuity
in fuse box.
FUEL LEVEL SENSOR SCREWS
All Models except SDI
Torque fuel level sensor retaining screws to 1 N•m
(8 lbf•in) in a criss-cross sequence and then to 2.4
N•m(21lbf•in), using the same sequence.
FUEL SYSTEM PRESSURIZATION
Fill up fuel tank.
Install on fuel tank, the special cap of leak testing
kit (P/N 529 033 100).
Using air pump from engine leak test kit (P/N 861
749 100), inject air into fuel tank. See next photo.
A32CBJA
1 2
TYPICAL
1. Special cap on tank
2. Air pump
Pressurize fuel system to 21 kPa (3 PSI). The pres-
sure must not drop during 3 minutes.
If pressure drops, locate fuel leak(s) and repair/
replace leaking component(s).
To ease locating leak(s) at fuel tank vent fitting,
fuel gauge or fuel cap, spray soapy water on com-
ponents; bubbles will indicate leak location(s).
mmr2004-Rev 161
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