Fuel Tank: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE EXHAUST PIPE ASSEMBLY CENTER
4. REMOVE FRONT FLOOR HEAT INSULATOR NO.3
a. Remove the 5 nuts and front floor heat insulator No.3
5. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1
a. Disengage the 4 grommets.
b. Remove the screw and fuel tank protector sub-assembly No.1.
6. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.3
a. Remove the nut and disconnect the parking brake cable assembly No.3.
7. DISCONNECT FUEL TANK WIRE
a. Separate the fuel tank wire connector from the bracket.
b. Disconnect the 2 connectors.
8. REMOVE CHARCOAL CANISTER PROTECTOR
a. Disconnect the clamp from the charcoal canister protector.
b. Remove the 3 bolts and charcoal canister protector.
9. DISCONNECT CHARCOAL CANISTER FUEL HOSE
a. Disconnect the charcoal canister fuel hose from the charcoal canister assembly.
1. Pinch the retainer and pull out the quick connector with the quick connector pushed to the pipe side to disconnect the charcoal canister fuel hose from the charcoal canister assembly.
NOTE:
- Remove dirt or foreign objects on the quick connector before this work.
- Be careful not to allow foreign matter to scratch or come into contact with the pipe that is sealed by O-rings.
- 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 plastic bag after disconnecting the charcoal canister fuel hose.
- If the quick connector and pipe are stuck, push and pull them to release. Clamp
10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Pinch the tabs of the retainer to disengage the lock claws and pull the retainer down as shown in the illustration.
b. Pull out the fuel tank main tube.
NOTE:
- Check for dirt or other foreign objects around the connector before this operation. Clean the connector as necessary.
- Be careful not to allow mud or foreign matter to scratch or come into contact with the pipe and connector that are sealed by O-rings.
- Do not use any tools for this operation.
- Do not damage the disconnected pipe and connector. Prevent intrusion of foreign objects by covering the pipe and connector with a plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release. Pull out the connector carefully.
11. DISCONNECT BREATHER LOWER TUBE
a. Remove the checker of the breather lower tube connector.
b. Pinch the retainer of the breather lower tube connector, and pull out the breather lower tube connector to disconnect the breather lower tube from the fuel tank.
NOTE:
- Check for dirt around the connector before this operation. Remove the dirt as necessary.
- Be careful not to allow mud or foreign matter to scratch or come into contact with the pipe and connector that are sealed by O-rings.
- Do not use any tool in this operation.
- Do not damage the disconnected pipe and connector. Prevent intrusion of foreign objects by covering the pipe and connector with a plastic bag.
- When the pipe and the connector are stuck, push and pull the connector to release. Pull out the connector carefully.
12. REMOVE FUEL TANK ASSEMBLY
a. Set a transmission jack to the fuel tank.
b. Remove the fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe.
c. Remove the 4 bolts and the fuel tank bands.
d. Operate the transmission jack, and disconnect the fuel inlet pipe.
e. Operate the transmission jack, and remove the fuel tank.
13. REMOVE FUEL PUMP AND GAUGE WITH SUCTION TUBE
a. Disconnect the fuel pump connector.
b. Disconnect the clamp and vapor pressure sensor connector.
c. Remove the tube joint clip and clamp, and pull out the fuel pump tube.
NOTE:
- Check for dirt around the fuel tube joint before this work. Clean the dirt away as necessary.
- Be careful not to allow dirt or foreign matter to scratch or come into contact with the fuel tube connector and fuel suction plate that are sealed by O-rings.
- Do not use any tools in this work.
- Do not bend or twist the nylon tube by force.
- Cover the disconnected fuel tube joint with a plastic bag.
- When the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube with the fingers, and turn it carefully to release. Disconnect the fuel tank tube.
d. Remove the 8 bolts, fuel tank vent tube set plate and fuel pump connector plate.
e. Pull out the fuel pump assembly from the fuel tank.
NOTE:
- Do not damage the fuel pump filter.
- Be careful not to bend the arm of the sender gauge.
f. Remove the gasket from the fuel suction tube.
14. DRAIN FUEL
15. REMOVE FUEL VAPOR CONTAINMENT VALVE
a. Disconnect the connector and clamp.
b. Remove the 2 nuts from the fuel vapor containment valve.
c. Push the fuel tank vent hose deep into the fuel tank to release the lock pin.
d. Pinch portion A.
e. Pull out the fuel tank vent hose.
f. Remove the fuel vapor containment valve from the fuel tank.
16. REMOVE FUEL TANK WIRE
a. Disconnect the 4 clamps, and remove the fuel tank wire.
17. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Remove the fuel tank main tube from the clamp.
18. REMOVE CLAMP
a. Remove the 2 clamps of the fuel tank main tube from the fuel tank.
b. Remove the clamp from the fuel tank.
19. REMOVE FUEL TANK CUSHION
a. Remove the 8 fuel tank cushions from the fuel tank.
INSTALLATION
1. INSTALL FUEL TANK CUSHION
a. Install 8 new fuel tank cushions to the fuel tank.
2. INSTALL CLAMP
a. Install the clamp to the fuel tank.
b. Install the 2 fuel tube clamps of the fuel tank main tube to the fuel tank.
3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Install the fuel tank main tube to the clamp.
4. INSTALL FUEL TANK WIRE
a. Install the fuel tank wire.
5. INSTALL FUEL VAPOR CONTAINMENT VALVE
a. Connect the fuel tank vent hose to the fuel tank.
b. Install the 2 nuts to the fuel vapor containment valve.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
c. Connect the connector and clamp.
6. INSTALL FUEL PUMP AND GAUGE WITH SUCTION TUBE
a. Install a new gasket on the fuel pump assembly.
b. Install the fuel pump assembly.
c. Install the fuel tank vent tube set plate by aligning it with the cutout on the fuel pump assembly.
d. Install the fuel tank vent tube set plate and fuel pump connector plate with the 8 bolts.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
e. Connect the fuel tank main tube with the tube joint clip and clamp.
NOTE:
- Check that there is no scratches or foreign objects on the connecting part.
- Check that the fuel tube joint is inserted securely.
- Check that the tube joint clip is on the collar of the fuel tube joint.
- After installing the tube joint clip, check that the fuel tube joint is pulled off.
f. Connect the fuel tank wire connector.
g. Connect the vapor pressure sensor connector and clamp.
7. INSTALL FUEL TANK ASSEMBLY
a. Set the fuel tank on a transmission jack.
b. Operate the transmission jack, and install the fuel tank to the vehicle.
c. Operate the transmission jack, and connect the fuel tank inlet pipe with the tube connector and clamp.
d. Install the 2 fuel tank bands with the 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
8. CONNECT BREATHER LOWER TUBE
a. Connect the breather lower tube.
1. Push in the tube connector to the pipe until the tube connector makes a "click" sound.
NOTE:
- Check for damage or foreign objects on the connected part of the fuel pipe.
- After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
b. Install the checker to the pipe.
9. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Connect the fuel tank main tube sub-assembly.
1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
NOTE:
- Check for damage or foreign objects on the connected part.
- After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
10. CONNECT CHARCOAL CANISTER FUEL HOSE
a. Align the quick connector with the pipe, then push in the quick connector until the retainer makes a "click" sound to connect the charcoal canister fuel hose to the charcoal canister assembly.
NOTE:
- Check for scratches or foreign objects around the connected part of the quick connector and pipe before this work.
- After connecting the charcoal canister fuel hose, check that the charcoal canister fuel hose is securely connected by pulling on the quick connector.
11. INSTALL CHARCOAL CANISTER PROTECTOR
a. Connect the clamp to the charcoal canister protector.
b. Install the charcoal canister protector with the 3 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
12. CONNECT FUEL TANK WIRE
a. Connect the fuel tank wire connectors, and install them to the bracket.
13. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.3
a. Install the parking brake cable assembly No.3 with the nut.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
14. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1
a. Install the fuel tank protector sub-assembly No.1 with the screw and the 4 grommets.
15. INSTALL FRONT FLOOR HEAT INSULATOR NO.3
a. Install the front floor heat insulator No.3 with the 5 nuts.
Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)
16. INSTALL EXHAUST PIPE ASSEMBLY CENTER
17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
18. ADD FUEL
19. CHECK FOR FUEL LEAKS
20. CHECK FOR EXHAUST GAS LEAKS
21. PERFORM INITIALIZATION
Some systems need initialization after reconnecting the cable to the negative battery terminal.