Fuel Tank: Service and Repair
Removal & Installation and Disassembly & Reassembly1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE REAR SEAT CUSHION ASSY LH
3. REMOVE REAR FLOOR SERVICE HOLE COVER
4. DISCHARGE FUEL SYSTEM PRESSURE
a. Start the engine.
b. After the engine has stopped on the its own, turn the ignition switch to lock.
5. REMOVE FUEL TANK PROTECTOR NO.2
6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY
7. REMOVE FUEL TANK VENT TUBE SET PLATE
8. REMOVE FUEL PUMP ASSEMBLY
9. REMOVE FUEL SUCTION TUBE SET GASKET
10. DRAIN FUEL
11. REMOVE FRONT DOOR SCUFF PLATE RH
12. REMOVE COWL SIDE TRIM BOARD RH
13. REMOVE REAR DOOR SCUFF PLATE RH
14. REMOVE CENTER PILLAR GARNISH LOWER RH
15. REMOVE FRONT SEAT ASSY RH
16. REMOVE EXHAUST PIPE ASSY CENTER
a. Disconnect the oxygen sensor connector.
b. Remove the 2 exhaust pipe supports.
c. Remove the bolt and clamp.
d. Remove the 2 bolts, 2 compression springs and exhaust pipe.
18. REMOVE FRONT FLOOR HEAT INSULATOR NO.1
a. Remove the 3 nuts and front floor heat insulator.
19. REMOVE FRONT FLOOR HEAT INSULATOR NO.2
a. Remove the 2 nuts and front floor heat insulator.
20. SEPARATE PARKING BRAKE CABLE ASSY NO.2
a. Remove the 3 installing bolts of the parking brake cable.
21. SEPARATE PARKING BRAKE CABLE ASSY NO.3
a. Remove the 3 installing bolts of the parking brake cable.
22. DISCONNECT CHARCOAL CANISTER OUTLET HOSE NO.1
a. Disconnect the charcoal canister outlet hose from the charcoal canister.
23. DISCONNECT FUEL EVAPORATION TUBE SUB-ASSY NO.3
a. Disconnect the fuel tank to canister tube from the charcoal canister.
b. Remove the fuel tank to canister tube from the 2 evaporation vent tube clamps.
24. DISCONNECT FUEL EMISSION TUBE NO.2
a. Disconnect the fuel emission tube from the charcoal canister.
b. Remove the fuel tank to canister tube from the 2 evaporation vent tube clamps.
25. DISCONNECT FUEL EVAPORATION TUBE SUB-ASSY NO.1
a. Pinch the fuel tube connector clip and then pull the fuel evaporation tube out of the pipe.
NOTE:
- Remove any dirt and foreign objects on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube joint has the O-ring that seals the plug.
- Do not use any tool.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag and gum tape after disconnecting the fuel pump tube.
- When the fuel tube connector and pipe are stuck, pinch the fuel evaporation tube between fingers, and turn it carefully to disconnect the fuel evaporation tube.
26. DISCONNECT FUEL TANK VENT HOSE
a. Disconnect the fuel tank bent hose from the charcoal canister.
1. Push the connector deep inside.
2. Pinch portion A.
3. Pull the connector out.
27. REMOVE CHARCOAL CANISTER ASSY
a. Disconnect the pressure switching valve connector.
b. Remove the 3 bolts and charcoal canister.
28. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY
a. Pinch the fuel tube connector clip, and remove the fuel tube connector clip.
b. Pull the fuel tank main tube out.
NOTE:
- Remove any dirt and foreign objects on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube joint has the O-ring that seals the plug.
- Do not use any tool.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag and gum tape after disconnecting the fuel pump tube.
- When the fuel tube connector and pipe are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to disconnect the fuel tank main tube.
29. DISCONNECT FUEL TANK INLET PIPE FUEL HOSE
a. Disconnect the fuel tank inlet pipe fuel hose from the fuel tank.
30. REMOVE FUEL TANK ASSY
a. Hold the fuel tank using a transmission jack.
b. Remove the 4 bolts and 2 fuel tank bands.
c. Operate the mission jack and then disconnect the 2 fuel tank breather hoses.
31. REMOVE FUEL TANK MAIN TUBE SUB-ASSY
a. Remove the fuel tank main tube from the fuel tube clamp.
32. REMOVE FUEL TUBE CLAMP NO.4
a. Remove the bolt and fuel tube clamp.
33. REMOVE FUEL TANK BREATHER HOSE
a. Remove the fuel breather hose from the fuel tank.
34. REMOVE FUEL EMISSION TUBE NO.2
a. Pinch the fuel tube connector clip and then pull the fuel emission tube out.
NOTE:
- Remove any dirt and foreign objects on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube joint has the O-ring that seals the plug.
- Do not use any tool.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag and gum tape after disconnecting the fuel pump tube.
- When the fuel tube connector and pipe are stuck, pinch the fuel emission tube between fingers, and turn it carefully to disconnect the fuel emission tube.
35. REMOVE EVAPORATION VENT TUBE CLAMP NO.2
a. Remove the bolt and evaporation vent tube clamp.
36. REMOVE CHECK VALVE PROTECTOR
a. Remove the 3 bolts and check valve protector.
37. REMOVE BREATHER TUBE SUB-ASSY
a. Pinch the fuel tube connector clip and then pull the breather tube out.
NOTE:
- Remove any dirt and foreign objects on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube joint has the O-ring that seals the plug.
- Do not use any tool.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag and gum tape after disconnecting the fuel pump tube.
- When the fuel tube connector and pipe are stuck, pinch the tube between fingers, and turn it carefully to disconnect the tube.
b. Remove the breather tube from the fuel tube bracket and clamp.
38. REMOVE FUEL TUBE BRACKET
a. Remove the fuel tube bracket from the fuel tank.
39. REMOVE FUEL TUBE CLAMP NO.2
a. Remove the fuel tube clamp from the fuel tank.
40. REMOVE FUEL TANK VENT HOSE
a. Disconnect the fuel tank bent hose from the charcoal canister.
1. Push the connector deep inside.
2. Pinch portion A.
3. Pull the connector out.
b. Remove the fuel tank vent hose from the fuel tube clamp.
41. REMOVE FUEL TUBE CLAMP NO.4
a. Remove the bolt and fuel tube clamp.
42. REMOVE FUEL TANK INLET VALVE ASSY
a. Remove the 3 bolt, check the valve support and fuel tank inlet valve.
43. REMOVE CHECK VALVE GASKET
a. Remove the gasket from the fuel tank inlet valve.
44. REMOVE FUEL TANK PROTECTOR NO.1
a. Using a drill, cut the flange portion of the rivet.
HINT: Wind tape so that the drill blade appears approx. 5.0 mm (0.197 in.) on the edge.
NOTE:
- Wind tape around the drill blade so that approximately 5.0 mm (0.197 in.) of the blade protrude from the tape.
- Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
- Be careful when performing this operation as the cut rivet is hot.
45. REMOVE FUEL TANK CUSHION NO.1
a. Remove the 10 fuel tank cushions from the fuel tank.
46. INSTALL FUEL TANK CUSHION NO.1
a. Install the 10 fuel tank cushions onto the fuel tank.
47. INSTALL FUEL TANK PROTECTOR NO.1
a. Using a riveter, install the fuel tank protector with the 4 new rivets.
HINT: Install the rivets while holding the materials tightly together to ensure a firm connection.
48. INSTALL CHECK VALVE GASKET
a. Install a new gasket onto the fuel tank inlet valve.
49. INSTALL FUEL TANK INLET VALVE ASSY
a. Install the fuel tank inlet valve and check valve support with the 3 bolts.
Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)
50. INSTALL FUEL TUBE CLAMP NO.4
a. Install the fuel tube clamp with the bolt.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
51. INSTALL BREATHER TUBE SUB-ASSY
a. Push the breather tube in the pipe until fuel tube connector makes a "click" sound.
NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
52. INSTALL CHECK VALVE PROTECTOR
a. Install the check valve protector with 3 bolts.
Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)
53. INSTALL EVAPORATION VENT TUBE CLAMP NO.2
a. Install the evaporation vent tube clamp with the bolt.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
54. INSTALL FUEL EMISSION TUBE NO.2
a. Push the fuel emission tube in the pipe until fuel tube connector makes a "click" sound.
NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
55. INSTALL FUEL TUBE CLAMP NO.4
a. Install the fuel tube clamp with the bolt.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
56. INSTALL FUEL TANK ASSY
a. Set the mission jack to the fuel tank.
b. Operate the mission jack and then connect the 2 fuel tank breather hoses.
c. Install 2 fuel tank bands with the 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
57. CONNECT FUEL TANK MAIN TUBE SUB-ASSY
a. Push the fuel tube connector in the pipe until fuel tube connector, and install the fuel tube connector clip.
NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
58. INSTALL CHARCOAL CANISTER ASSY
a. Install the charcoal canister with 3 bolts.
Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
b. Connect pressure switching valve connector.
59. CONNECT FUEL EVAPORATION TUBE SUB-ASSY NO.1
a. Push the fuel evaporation tube in the pipe until fuel tube connector makes a "click" sound.
NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
60. INSTALL PARKING BRAKE CABLE ASSY NO.2
a. Install the parking brake cable with 3 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.Vlbf)
61. INSTALL PARKING BRAKE CABLE ASSY NO.3
a. Install the parking brake cable with 3 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
62. INSTALL FRONT FLOOR HEAT INSULATOR NO.2
a. Install the front floor heat insulator with 2 nuts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
63. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
a. Install the front floor heat insulator with 3 nuts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
64. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY
65. INSTALL EXHAUST PIPE ASSY CENTER
a. Using vernier calipers, measure the free length of the compression spring.
Free length: 40mm (1.5748 in.)
b. Install a new gasket onto the exhaust pipe front.
c. Install a new gasket onto the exhaust pipe center (rear side).
d. Install the exhaust pipe center with the 2 compression springs, clamp and 3 bolts.
Torque:
Front 43 N.m (440 kgf.cm, 32 ft.lbf)
Rear 32 N.m (330 kgf.cm, 24 ft.lbf)
e. Install the 2 exhaust pipe supports.
f. Connect the oxygen sensor connector.
66. INSTALL FRONT SEAT ASSY RH
67. INSTALL FUEL SUCTION TUBE SET GASKET
68. INSTALL FUEL PUMP ASSEMBLY
69. INSTALL FUEL TANK VENT TUBE SET PLATE
70. CONNECT FUEL TANK MAIN TUBE SUB-ASSY
71. INSTALL FUEL TANK PROTECTOR NO.2
72. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
73. CHECK FOR FUEL LEAKAGE
74. CHECK FOR EXHAUST GAS LEAKAGE
75. INSTALL REAR FLOOR SERVICE HOLE COVER
76. INSTALL REAR SEAT CUSHION ASSY LH