Fuel Tank: Service and Repair

3.2L





3.2L Rodeo

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 Section Driveability and Emissions.

1. Drain the fuel from the fuel tank, refer to Fuel Pump Flow Test.
2. Disconnect battery ground cable.
3. Loosen fuel filler cap to reduce the pressure in fuel tank.
4. Support underneath of the fuel tank assembly (1) with a lifter.
5. Disconnect fuel feed hose (7) and fuel return hose (8) near the fuel filter.

NOTE: Plug both ends of the fuel hoses to prevent fuel leakage.
6. Disconnect fuel filler hose (5) and fuel vent hose (6) at the fuel filler neck.

NOTE: Cover fuel hoses to prevent any dust entering.

7. Remove two bolts (4) and remove separator.
8. Remove the five fuel tank assembly fixing bolts (2) and one nut (3).

INSTALLATION
1. Raise the fuel tank assembly (1) and connect the wiring connectors (9, 10).
2. Install fuel tank assembly along with protectors and tighten the five fixing bolts (2) and one nut (3) to the specified torque.

Torque: 68 N.m (50 lb ft)

3. Install the separator and tighten two bolts (4).

Torque: 10 N.m (95 lb in)

4. Connect fuel filler hose (5) and fuel vent hose and clip them firmly.
5. Connect fuel feed hose and fuel return hose (8), and clip them firmly.
6. Tighten fuel filler cap until at least three clicks are heard.
7. Connect battery ground cable.

3.2L Rodeo Sport

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, refer to "Driveability and Emissions".

1. Drain the fuel from the fuel tank, refer to "Fuel Pump Flow Test" in this section.
2. Disconnect battery ground cable.
3. Loosen fuel filler cap to reduce the pressure in fuel tank.
4. Support underneath of the fuel tank (4) with a lifter.
5. Disconnect fuel feed hose (7) and fuel return hose (8) near the fuel filter..
6. Disconnect air breather hose (1) and fuel filler hose (3) at the fuel filler neck.

Note: Cover fuel hose to prevent any dust entering.

7. Remove the five fuel tank assembly fixing bolts (5) and one nut (6).
8. Lower the tank and disconnect the wiring connectors (10, 11).
9. Remove fuel tank assembly along with protectors.

INSTALLATION
1. Lift up fuel tank assembly and connect the wiring connectors (10, 11).
2. Install fuel tank assembly along with protectors and tighten the six fixing bolts to the specified torque.

Torque: 68 N.m (50 lb ft)

3. Connect fuel filler hose (3) and air breather hose (1), and clip them firmly.
4. Connect fuel feed hose and fuel return hose, and clip them firmly.
5. Tighten fuel filler cap until at least three clicks are heard.
6. Connect battery ground cable.