Fuel Tank: Service and Repair
REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY1. PREVENT GASOLINE FROM SPILLING OUT
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE REAR FLOOR SERVICE HOLE COVER
5. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY
6. REMOVE FUEL TANK VENT TUBE SET PLATE
7. REMOVE FUEL SUCTION TUBE ASSEMBLY W/ PUMP & GAUGE
8. DRAIN FUEL
9. REMOVE EXHAUST PIPE ASSEMBLY CENTER
10. DISCONNECT PARKING BRAKE CABLE ASSEMBLY NO.2
a. Remove the set bolt and set nut of the parking brake cable assembly No.2.
11. DISCONNECT PARKING BRAKE CABLE ASSEMBLY NO.3
a. Remove the set bolt and set nut of the parking brake cable assembly No.3.
12. REMOVE FUEL TANK PROTECTOR LOWER CENTER
a. Remove the 4 bolts and fuel tank protector.
13. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel pump tube.
1. Pinch the tab of the retainer to remove the lock claws and pull it down as shown.
2. Pull out the fuel tank main tube.
NOTE:
- Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
- Be careful of mud because the quick connector has O-rings which seal the pipe and connector that can be contaminated.
- Do not use any tools in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
b. Disconnect the fuel tube No.1.
1. Pinch the tube connector and then pull out the fuel tube No.1.
NOTE:
- Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
- Be careful of mud because the quick connector has O-rings which seal the pipe and connector that can be contaminated.
- Do not use any tools in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
c. Set up a transmission jack underneath the fuel tank.
d. Remove the 2 set bolts of the fuel tank bands.
e. Remove the hose clamp and disconnect the fuel tank to filler pipe hose.
f. Disconnect the fuel tank vent hose from the charcoal canister.
1. Push the connector deep into the charcoal canister to release the locking pin.
2. Pinch portion A.
3. Pull out the connector.
g. Remove the fuel tank.
h. Remove the 2 pins and 2 fuel tank bands as shown in the illustration.
i. Remove the 4 clip nuts.
14. REMOVE FUEL TANK VENT HOSE
a. Push the connector deep into the charcoal canister to release the locking pin.
b. Pinch portion A.
c. Pull out the connector.
15. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY
a. Remove the fuel pump tube from the fuel main tube support.
16. REMOVE FUEL MAIN TUBE SUPPORT
a. Remove the bolt and tube support.
17. REMOVE FUEL TANK CUSHION NO.2
a. Remove the 7 fuel tank cushion No.2.
18. INSTALL FUEL TANK CUSHION NO.2
a. Install the 7 new fuel tank cushions to the fuel tank.
19. INSTALL FUEL MAIN TUBE SUPPORT
a. Install the fuel main tube support with the bolt.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
20. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY
a. Install the fuel pump tube to the fuel main tube support.
21. INSTALL FUEL TANK VENT HOSE
a. Install the fuel tank vent hose.
22. INSTALL FUEL TANK ASSEMBLY
a. Install the 4 clip nuts.
b. Install the 2 fuel tank bands with the 2 pins.
c. Connect the fuel tank vent hose.
d. Connect the fuel tank inlet pipe with the fuel filler pipe clamp.
e. Tighten the 2 set bolts of the fuel tank bands.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
f. Connect the fuel tube No.1.
1. Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound.
NOTE:
- Check that there is no damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart.
g. Connect the fuel pump tube.
1. Push in the fuel tube connector to the pipe and push up the retainer so that the claws engage.
NOTE:
- Check that there is no damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart.
23. INSTALL FUEL TANK PROTECTOR LOWER CENTER
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
24. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.3
a. Install the parking brake cable assembly No.3 with the bolt and nut.
Torque:
Bolt: 6.0 N.m (61 kgf.cm, 53 in.lbf)
Nut: 8.5 N.m (87 kgf.cm, 75 in.lbf)
25. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.2
a. Install the parking brake cable assembly No.2 with the bolt and nut.
Torque:
Bolt: 6.0 N.m (61 kgf.cm, 53 in.lbf)
Nut: 8.5 N.m (87 kgf.cm, 75 in.lbf)
26. INSTALL EXHAUST PIPE ASSEMBLY CENTER
27. INSTALL FUEL SUCTION TUBE ASSEMBLY W/ PUMP & GAUGE
28. INSTALL FUEL TANK VENT TUBE SET PLATE
29. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY
30. ADD FUEL
31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
32. CHECK FOR FUEL LEAKS
33. CHECK FOR EXHAUST GAS LEAKS
34. INSTALL REAR FLOOR SERVICE HOLE COVER
35. INSTALL REAR SEAT CUSHION ASSEMBLY
36. PERFORM INITIALIZATION
Some systems need initialization when disconnecting the battery terminal.