Fuel Tank Removal and Replacement
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
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 WITH PUMP AND GAUGE
8. DRAIN FUEL
9. REMOVE NO. 1 FLOOR UNDER COVER
a. Loosen the 6 grommets and remove the No. 1 floor under cover.
10. REMOVE NO. 2 FLOOR UNDER COVER
a. Remove the 2 clips.
b. Loosen the 6 grommets and remove the No. 2 floor under cover.
11. REMOVE CENTER EXHAUST PIPE ASSEMBLY.
12. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY
a. Remove the set bolt and set nut of the No. 2 parking brake cable assembly.
13. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY
a. Remove the set bolt and set nut of the No. 3 parking brake cable assembly.
14. REMOVE REAR STABILIZER BAR NO. 1 BRACKET
a. Remove the 4 bolts and 2 rear stabilizer bar No. 1 brackets.
15. REMOVE FUEL TANK PROTECTOR LOWER CENTER
a. Remove the 4 bolts and fuel tank protector lower center.
16. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel pump tube.
1. Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration.
2. Pull out the fuel tank main tube.
NOTE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector as necessary.
- It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Remove the quick connector by hand.
- Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
b. Disconnect the No. 1 fuel tube.
1. Pinch the tube connector and then pull out the No. 1 fuel tube.
NOTE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector as necessary.
- It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Remove the quick connector by hand.
- Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
c. Disconnect the fuel filler pipe.
1. Remove the 2 bolts from the fuel tank filler pipe support.
2. Remove the fuel filler pipe clamp.
NOTE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
- It is necessary to prevent mud or dirt from entering the fuel filler pipe. If mud or dirt gets in the fuel filler pipe, the Orings may not seal properly.
- Remove the fuel filler pipe by hand.
- Protect the fuel filler pipe by covering it with a plastic bag.
- If the fuel filler pipe and fuel tank are stuck, carefully try wiggling or pushing and pulling on the fuel filler pipe to release it. Pull the fuel filler pipe off the fuel tank carefully.
d. Disconnect the fuel tank vent hose from the charcoal canister.
1. Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration.
2. Pull out the fuel tank vent hose from the charcoal canister.
NOTE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector as necessary.
- It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Remove the quick connector by hand.
- Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
e. Place an engine lifter under the fuel tank assembly.
f. Remove the 2 set bolts of the fuel tank bands.
g. Slightly lower the transmission jack.
h. Remove the fuel tank.
i. Remove the 2 pins and 2 fuel tank bands as shown in the illustration.
j. Remove the 4 clip nuts.
17. REMOVE FUEL VAPOR CONTAINMENT VALVE
18. REMOVE FUEL SOLENOID VALVE RETURN BRACKET
19. REMOVE NO. 1 FUEL TUBE CLAMP
20. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY
a. Remove the fuel pump tube from the fuel main tube support.
21. REMOVE FUEL MAIN TUBE SUPPORT
a. Remove the bolt and tube support.
22. REMOVE NO. 2 FUEL TANK CUSHION
a. Remove the 7 No. 2 fuel tank cushions.
INSTALLATION
1. INSTALL NO. 2 FUEL TANK CUSHION
a. Install 7 new No. 2 fuel tank cushions to the fuel tank.
2. 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)
3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY
a. Install the fuel pump tube to the fuel main tube support.
4. INSTALL NO. 1 FUEL TUBE CLAMP
5. INSTALL FUEL SOLENOID VALVE RETURN BRACKET
6. INSTALL FUEL VAPOR CONTAINMENT VALVE
7. INSTALL FUEL TANK ASSEMBLY
a. Install the 4 clip nuts.
b. Install the 2 fuel tank bands with the 2 pins.
c. Set the fuel tank assembly onto the transmission jack.
d. Raise the transmission jack.
NOTE: Slowly raise the jack to prevent the fuel tank assembly from dropping.
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 tank vent hose to the charcoal canister.
1. Push the quick connector into the pipe and push up the retainer so that the claws engage.
NOTE:
- Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
- After connecting, check if the quick connector and the charcoal canister are securely connected by pulling on them.
g. Connect the fuel filler pipe.
1. Install the fuel tube connector to the fuel filler pipe.
2. Install the fuel filler pipe clamp.
NOTE:
- Before connecting the pipe, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
- After connecting, check if the fuel filler pipe and the fuel tank are securely connected by pulling on them.
3. Install the 2 bolts to the fuel tank filler pipe support.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
h. Connect the No. 1 fuel tube.
1. Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound.
NOTE:
- Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
- After connecting, check if the fuel tube connector and the fuel tank are securely connected by pulling on them.
i. Connect the fuel pump tube.
1. Push the fuel connector into the pipe and push up the retainer so that the claws engage.
NOTE:
- Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
- After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them.
8. INSTALL FUEL TANK PROTECTOR LOWER CENTER
a. Install the 4 bolts and fuel tank protector lower center.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
9. INSTALL REAR STABILIZER BAR NO. 1 BRACKET
a. Install the 2 rear stabilizer bar No. 1 brackets with the 4 bolts.
Torque: 31 N.m (316 kgf.cm, 23 ft.lbf)
10. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY
a. Install the No. 3 parking brake cable assembly 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)
11. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY
a. Install the No. 2 parking brake cable assembly 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)
12. INSTALL CENTER EXHAUST PIPE ASSEMBLY.
13. INSTALL NO. 1 FLOOR UNDER COVER
a. Install the No. 1 floor under cover with the 6 grommets.
14. INSTALL NO. 2 FLOOR UNDER COVER
a. Install the No. 2 floor under cover with the 2 clips and 6 grommets.
15. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
16. INSTALL FUEL TANK VENT TUBE SET PLATE
17. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY
18. ADD FUEL 19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
20. INSPECT FOR FUEL LEAK
21. INSPECT FOR EXHAUST GAS LEAK
22. INSTALL REAR FLOOR SERVICE HOLE COVER
23. INSTALL REAR SEAT CUSHION ASSEMBLY
24. PERFORM INITIALIZATION
a. Perform initialization procedure.
HINT: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.