Fuel Tank: Service and Repair
Removal & Installation and Disassembly & Reassembly1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE REAR SEAT CUSHION ASSEMBLY 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-ASSEMBLY
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 ASSEMBLY RH
16. REMOVE EXHAUST PIPE ASSEMBLY 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.
17. REMOVE PROPELLER W/CENTER BEARING SHAFT
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 ASSEMBLY NO.2
a. Remove the 3 installing bolts of the parking brake cable.
21. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.3
a. Remove the 3 installing bolts of the parking brake cable.
22. REMOVE CHARCOAL CANISTER ASSEMBLY
a. Disconnect the pump module connector.
b. Remove the nut.
c. Disconnect the air inlet line hose from the air filter.
1. Push the connector deep inside.
2. Pinch portion A.
3. Pull the connector out.
NOTE:
- Remove dirt or foreign objects on the fuel tank vent connector before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tank vent connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tank vent hose.
- If the fuel tank vent connector and pipe are stuck,push and pull them to release.
d. Disconnect the air filter.
e. Disconnect the purge line hose.
1. Pinch the purge hose connector clip and then pull the purge line hose out of the canister.
f. Disconnect the vent line hose.
1. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and slide it as down in the illustration.
2. Pull the fuel tank vent hose out of the charcoal canister.
NOTE:
- Remove any dirt or foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tank vent hose.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
g. Remove the 2 bolts and disconnect the charcoal canister bracket.
h. Remove the bolt and charcoal canister assembly.
23. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
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.
24. DISCONNECT FUEL TANK INLET PIPE FUEL HOSE
a. Disconnect the fuel tank inlet pipe fuel hose from the fuel tank.
25. REMOVE FUEL TANK BAND
a. Hold the fuel tank using a transmission jack.
b. Remove the 4 bolts and 2 fuel tank banks.
26. DISCONNECT HOSES
a. Operate the transmission jack.
b. Disconnect the fuel tank breather hose.
c. Pinch the purge line hose connector clip and the pull the purge line hose out.
d. Disconnect the air inlet line hose from the air filter.
1. Push the connector deep inside.
2. Pinch portion A.
3. Pull the connector out.
NOTE:
- Remove dirt or foreign objects on the fuel tank vent connector before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tank vent connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tank vent hose.
- If the fuel tank vent connector and pipe are stuck,push and pull them to release.
27. REMOVE AIR INLET LINE HOSE AND PURGE LINE HOSE
a. Disconnect the air inlet line hose from the fuel tube clamp No.2.
b. Remove the bolt, air inlet line hose and purge line hose.
28. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Remove the fuel tank main tube from the fuel tube clamp.
29. REMOVE FUEL TUBE CLAMP NO.4
a. Remove the bolt and fuel tube clamp.
30. REMOVE CHECK VALVE PROTECTOR
a. Remove the 3 bolts and check valve protector.
31. REMOVE BREATHER TUBE SUB-ASSEMBLY
a. Pinch the 2 fuel tube connector clips 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.
32. REMOVE FUEL TUBE CLAMP NO.2
a. Remove the fuel tube clamp from the fuel tank.
33. 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.
34. REMOVE FUEL TUBE CLAMP NO.4
a. Remove the bolt and fuel tube clamp.
35. REMOVE FUEL TANK INLET VALVE ASSEMBLY
a. Remove the 3 bolt, check the valve support and fuel tank inlet valve.
36. REMOVE CHECK VALVE GASKET
a. Remove the gasket from the fuel tank inlet valve.
37. REMOVE FUEL TANK PROTECTOR NO.1
a. Remove the nut.
b. 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.
38. REMOVE FUEL TANK CUSHION NO.1
a. Remove the 10 fuel tank cushions from the fuel tank.
39. INSTALL FUEL TANK CUSHION NO.1
a. Install the 10 fuel tank cushions onto the fuel tank.
40. 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.
b. Install the nut.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
41. INSTALL CHECK VALVE GASKET
a. Install a new gasket onto the fuel tank inlet valve.
42. INSTALL FUEL TANK INLET VALVE ASSEMBLY
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)
43. 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)
44. INSTALL BREATHER TUBE SUB-ASSEMBLY
a. Push the breather tube in the pipe until 2 fuel tube connectors 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.
45. INSTALL CHECK VALVE PROTECTOR
a. Install the check valve protector with 3 bolts.
Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)
46. 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.
47. 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)
48. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
49. INSTALL AIR INLET LINE HOSE AND PURGE LINE HOSE
a. Install the air inlet line hose and purge line hose with the bolt.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
b. Connect the air inlet line hose to the fuel tube clamp No.2.
50. CONNECT HOSES
a. Set the transmission jack to the fuel tank.
b. Operate the transmission jack.
c. Push the purge line hose connector in the pipe until hose connector, and install the purge line hose connector clip.
NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the hose connector and pipe are securely connected by pulling them.
d. Push the air inlet line hose connector in the pipe until hose connector, and install the air inlet line hose connector clip.
NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the hose connector and pipe are securely connected by pulling them.
51. INSTALL FUEL TANK BAND
a. Operate the transmission jack.
b. Install the 2 fuel tank bands with the 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
52. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
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.
53. INSTALL CHARCOAL CANISTER ASSEMBLY
a. Install the charcoal canister assembly with the bolt.
Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
b. Install the charcoal canister bracket with the 4 bolts.
Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
c. Connect the vent line hose.
1. Align the vent line hose connector with the pipe, then push in the vent line hose connector until the contacts the seat to contact the vent line hose to the pipe, then push up the retainer to the claws lock.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the vent line hose connector and pipe before performing this work.
- After connecting the vent line hose, check that the vent line hose is securely connected by pulling the vent line hose connector and pipe.
d. Connect the purge line hose.
1. Push the purge line hose connector makes a "click" sound.
NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting the purge line hose, check that the purge line hose is securely connected by pulling the quick connector.
e. Connect the air filter.
f. Connect the air inlet line hose to the air filter.
1. Align the vent line hose connector with the pipe, then push in the vent line hose connector until the retainer makes a "click" sound to connect the vent line hose to the charcoal canister.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the vent line hose connector and pipe before this work.
- After connecting the vent line hose, check that the vent line hose is securely connected by pulling the quick connector.
g. Install the clip.
h. Connect the pump module connector.
54. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.2
a. Install the parking brake cable with 3 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
55. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.3
a. Install the parking brake cable with 3 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
56. 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)
57. 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)
58. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
59. INSTALL EXHAUST PIPE ASSEMBLY CENTER
a. Using vernier calipers, measure the free length of the compression spring.
Free length: 40 mm (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.
60. INSTALL FRONT SEAT ASSEMBLY RH
61. INSTALL FUEL SUCTION TUBE SET GASKET
62. INSTALL FUEL PUMP ASSEMBLY
63. INSTALL FUEL TANK VENT TUBE SET PLATE
64. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
65. INSTALL FUEL TANK PROTECTOR NO.2
66. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
67. CHECK FOR FUEL LEAKAGE
68. CHECK FOR EXHAUST GAS LEAKAGE
69. INSTALL REAR FLOOR SERVICE HOLE COVER
70. INSTALL REAR SEAT CUSHION ASSEMBLY LH