Fuel Tank Removal and Installation

This article has been updated by techincal service bulletin TSB 06-30-001 dated JANUARY, 2006.

The 2003-2005 Accent Shop Manuals contain incorrect information for the fuel filter location.

VEHICLES AFFECTED:
Model: 2003-2005 Accent
Affected vehicle production date range:
- 3 door model: Produced June 6, 2003 - End of 2005MY
- 4 door model: Produced June 10, 2003 - End of 2005MY






For the 2003-2005MY the fuel filter is incorporated into the fuel pump assembly within the fuel tank.
- Part Number: 31112-25700 (Filter-Fuel Injection Pump).

Components:

REMOVAL




1. Press the two taps under the rear seat and raise the seat, then detach the inspection panel of the fuel pump.
2. To reduce the internal pressure of the fuel lines and hoses, first start the engine with the fuel pump disconnected and wait until it stops by itself.

NOTE: Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose, otherwise fuel will spill out.




3. Disconnect the battery cable from the negative terminal of the battery.
4. Disconnect the high pressure hose from the fuel filter output side, and disconnect the tap for static electricity.

CAUTION: Cover the hose connection with a shop tower to prevent splashing of fuel that could be caused by residual pressure in the fuel line.

5. Lift up the vehicle.
6. Detach the fuel filler hose and leveling hose.
7. Support the fuel tank with a jack.




8. Remove the fuel tank bands.
9. Remove the fuel tank.

INSPECTION

1. Check the hoses and the pipes for cracks or damage.
2. Check the fuel tank cap for proper operation.
3. Check the fuel tank for deformation, corrosion or cracking.
4. Check the inside of the fuel tank for dirt or foreign material.
5. Check the in-tank fuel filter for damage or restriction.
6. Test the two-way valve for proper operation




7. To check the two-way valve, lightly blow into the inlet and outlet. If air passes through after slight resistance, then the valve is good.

INSTALLATION




1. Confirm that the pad is fully bonded to the fuel tank, and install the fuel tank by tightening the self-locking nuts.
2. Connect the leveling hose to the tank and at the tiller neck by approximately 40 mm (1.6 in.).




3. When connecting the filler hose, the end with the shorter straight pipe should be connected to the tank side.
4. Connect the vapor hose. When attaching the vapor hose to the line, be sure that the hose is attached as shown in the illustration.
5. Connect the high pressure hose to the fuel pump. Be careful that the fuel hose does not twist
6. Connect the electrical fuel pump connector.