Since we already had the lines off the fuel pump we started by replacing these. They are fairly short as they run to hard lines that run down the front of the tank. Unfortunately the ends are underneath the parcel shelf so replacing them is extremely difficult. Removing them is done completely by feel and small hands are a necessity. It took me 2 hours just to wriggle off the spring clips and get the lines freed. The above photo shows where those lines route and also shows the clamp that secures them to the tank. If you follow the link, you can see what a rusty Cappuccino fuel tank looks like. SourceUnder the car, the fuel filter is attached to the rear subframe. It is easier to unbolt the clamp from the subframe and remove both the clamp and filter as one unit. There are three sets of rubber lines to remove as well. One is for the feed (with the fuel filter in the middle), one for the return, and one for the EVAP system.The 8mm hex bolt that secures the filter is in an awkward spot when mounted to the car. Removing the filter from the clamp is much easier on the bench.For the fuel filter we’re swapping to a filter from a 2001-2007 Grand Vitara SUV. The filter is the same OD and has the same inlets and outlets as the Cappuccino’s filter, but it’s much longer. This will give us more filter area and should increase the service life of the filter. This filter can be acquired at any auto parts store so this is a great drop in replacement for a US Cappuccino owner.The Grand Vitara filter is around ¾” longer. The inlets and outlets are in the same location and the indents that locate and clock the filter in the bracket are all the same.There are some very minor differences in the exact location of the inlet and outlet, but all of these can be accounted for by cutting new fuel lines which we are doing anyway. We also cut new return and vent lines using the old lines as templates.
This is a cool project. Getting all the power back is a huge deal at such low numbers lol. I have really considered picking up an AZ-1. Didn’t you make a comparison article where you decided between the Cappucino, AZ-1, and the Beat?
We have not done a full comparison of the ABC cars. I’ve test driven a couple of Beats and ridden in an AZ-1. In our Project intro for the Cappuccino I discussed my reasoning for picking a Cappuccino over a Beat or AZ-1. I think I would quickly summarize them thusly:
AZ-1: Most expensive of the 3 due to its rarity (about double the price of a Cappuccino). Very cramped. No trunk or frunk. But man are they cool. It really is a mini DeLorean: awesome to look at and you’ll get a ton of questions but not the best day to day car. Also the cabin is a glass bubble so they get very hot in the summer.
Beat: Usually the cheapest of the three. Super fun to drive, and they’re great with the top down. But slow as hell. Naturally aspirated 660cc engine just has no torque. Great engines once they’re wound up a bit. Great cruiser especially if you live somewhere you can have the roof down all the time. Great interior too. IIRC, the roomiest of the 3. The trunk is pretty small but the interior has lots of storage. Beware of leaky roofs. I’ve heard they’re not too hard or expensive to replace though.
Cappuccino: Probably the best all rounder. Has a real trunk. Has a decent interior. 3-piece roof is great. Definitely the best for performance and the fastest of the 3 (that’s not saying much though). Lots of aftermarket support even today. I’ve had mine for 7 years now and still love it.
For any of them there are a few things to keep in mind. Not sure where you’re from, but if you’re in the US, you will need to either be a good DIY mechanic, or line up a shop that is willing to work on your car. A lot of shops won’t work on them. The Cappuccino has an English service manual, not sure if the AZ-1 or Beat do. Make sure you inspect your car thoroughly. DIY maintenance on all of these cars is tough. Everything is small and cramped so you have to get creative working on them. All of these cars have a tendency to rust and sometimes it is not obvious. The cheapest route is the DIY import route but it’s the riskiest. Rust will be hard to spot in the port photos and you won’t be able to drive the car until it’s already yours. I’ve heard a number of horror stories from DIY importing. A car that’s already imported, either by a dealer or privately, saves a lot of time and hassle and you can actually drive and inspect the car you want to buy. Finally, remember that these are hard cars to live with. They’re impractical, hard to maintain, and old. But any of the ABC cars is a blast to drive and people ask about them all the time. I highly recommend getting an ABC kei car, just be prepared for what you’re getting into.
That fuel pump was plenty for Project S2000 with the turbo added, so you’ll have all the headroom you need for more power 🙂 While the fuel system wasn’t the root cause of your issue, it was good to upgrade everything on a car that old!
3 comments
This is a cool project. Getting all the power back is a huge deal at such low numbers lol. I have really considered picking up an AZ-1. Didn’t you make a comparison article where you decided between the Cappucino, AZ-1, and the Beat?
Hey James,
We have not done a full comparison of the ABC cars. I’ve test driven a couple of Beats and ridden in an AZ-1. In our Project intro for the Cappuccino I discussed my reasoning for picking a Cappuccino over a Beat or AZ-1. I think I would quickly summarize them thusly:
AZ-1: Most expensive of the 3 due to its rarity (about double the price of a Cappuccino). Very cramped. No trunk or frunk. But man are they cool. It really is a mini DeLorean: awesome to look at and you’ll get a ton of questions but not the best day to day car. Also the cabin is a glass bubble so they get very hot in the summer.
Beat: Usually the cheapest of the three. Super fun to drive, and they’re great with the top down. But slow as hell. Naturally aspirated 660cc engine just has no torque. Great engines once they’re wound up a bit. Great cruiser especially if you live somewhere you can have the roof down all the time. Great interior too. IIRC, the roomiest of the 3. The trunk is pretty small but the interior has lots of storage. Beware of leaky roofs. I’ve heard they’re not too hard or expensive to replace though.
Cappuccino: Probably the best all rounder. Has a real trunk. Has a decent interior. 3-piece roof is great. Definitely the best for performance and the fastest of the 3 (that’s not saying much though). Lots of aftermarket support even today. I’ve had mine for 7 years now and still love it.
For any of them there are a few things to keep in mind. Not sure where you’re from, but if you’re in the US, you will need to either be a good DIY mechanic, or line up a shop that is willing to work on your car. A lot of shops won’t work on them. The Cappuccino has an English service manual, not sure if the AZ-1 or Beat do. Make sure you inspect your car thoroughly. DIY maintenance on all of these cars is tough. Everything is small and cramped so you have to get creative working on them. All of these cars have a tendency to rust and sometimes it is not obvious. The cheapest route is the DIY import route but it’s the riskiest. Rust will be hard to spot in the port photos and you won’t be able to drive the car until it’s already yours. I’ve heard a number of horror stories from DIY importing. A car that’s already imported, either by a dealer or privately, saves a lot of time and hassle and you can actually drive and inspect the car you want to buy. Finally, remember that these are hard cars to live with. They’re impractical, hard to maintain, and old. But any of the ABC cars is a blast to drive and people ask about them all the time. I highly recommend getting an ABC kei car, just be prepared for what you’re getting into.
That fuel pump was plenty for Project S2000 with the turbo added, so you’ll have all the headroom you need for more power 🙂 While the fuel system wasn’t the root cause of your issue, it was good to upgrade everything on a car that old!