Fuel Tank: Service and Repair
FUEL TANK AND ASSOCIATED PARTS:
Fuel Tank and Associated Parts
REMOVAL
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, See Computers and Control systems / System diagnosis.
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Support underneath of the fuel tank protector (15) with a lifter.
4. Disconnect evaporative fuel hose (3) at the canister.
5. Disconnect fuel feed hose (17) and fuel return hose (18) near the fuel filter.
NOTE: Plug both ends of the fuel hoses to prevent fuel leakage.
6. Disconnect air breather hose (4) and fuel filler hose (5) at the fuel filler neck.
NOTE: Cover fuel hose to prevent any dust entering.
7. Remove the four fuel tank assembly fixing bolts (14) at four corners of the tank.
8. Let down the tank and disconnect the wiring connectors (8,9).
9. Remove fuel tank assembly along with protectors (15,19).
10. Remove retaining cover (2) and roll over & float valve (1) along with the evaporative fuel hose and pipe (3).
11. Remove fuel pump and sender assembly (10) by removing the snap ring (7) along with the fuel hoses (17,18).
12. Remove protectors (15,19) by removing the six fixing bolts (6).
INSTALLATION
1. Install protectors (15,19) and tighten the six fixing bolts to the specified torque.
Torque: 68 Nm (50 lb ft)
2. Install fuel pump and sender assembly by fitting in of the snap ring (7).
3. Install roll over & float valve (1) by fitting in of the retaining cover (2).
4. Lift up fuel tank assembly and connect the wiring connectors (8,9).
5. Install fuel tank assembly along with protectors and tighten the four fixing bolts to the specified torque.
Torque: 68 Nm (50 lb ft)
6. Connect fuel filler hose (5) and air breather hose (4), and clip them firmly.
7. Connect fuel feed hose (17) and fuel return hose (18), and clip them firmly.
8. Connect evaporative fuel hose (3).
9. Tighten fuel filler cap.
10. Connect battery ground cable.