Fuel Tank: Service and Repair

FUEL TANK




Removal and Installation

REMOVAL
1. Release the fuel pressure from the fuel system.
Refer to "FUEL PRESSURE RELEASE" (QG18DE), "FUEL PRESSURE RELEASE" (QR25DE).
2. Disconnect the battery ground cable.
3. Open the fuel filler lid and remove the filler cap to relieve the pressure in the fuel tank.
4. Drain the fuel from the fuel tank. Refer to "General Precautions".
5. Remove the rear seat cushion. Refer to "Removal and Installation".




6. Remove the inspection hole cover located under the rear seat cushion by rotating the attaching clips 90 ° as shown.




7. Disconnect the fuel pump assembly electrical connector.




8. Disconnect the fuel feed hose quick connector as follows:
a. Apply mating marks on the fuel pump outlet and the quick connector for installation.
b. Hold the quick connector and push in the tabs, then pull out from of the fuel pump outlet that is inserted in the quick connector.

CAUTION:
- The quick connector can be removed when the tabs are completely depressed. Do not twist the fuel feed hose more than necessary.
- Do not use any tools to remove the quick connector.

9. Remove the center exhaust tube. Refer to "Removal and Installation".




10. From the rear left area of the fuel tank, remove the filler hose, vent hose, and evaporation hoses as shown.




11. Support the fuel tank with a suitable transmission jack as shown.
12. Remove the fuel tank mounting band bolts while supporting the fuel tank.




13. Lower the fuel tank by 70 - 80 mm (2.76 - 3.15 in), then remove the nuts and clips holding the fuel tank protector, and remove the protector.
- To remove the clips, use pliers to squeeze the extensions as shown by the arrows, and then remove the clip.

14. Remove the fuel tank.

INSTALLATION
Installation is in the reverse order of removal.
- Connect the quick connector in the order as follows:
- Align mating marks on the fuel pump outlet and the quick connector for correct installation.
- Align the push tabs with the quick connector slots.




- Insert the fuel pump outlet into the center of the quick connector until you hear a click.

- After connecting the quick connector, check that the quick connector is fully seated in the order as follows:




- Pull on the quick connector to make sure it is firmly connected.
- Apply fuel pressure to the fuel lines by turning the ignition switch ON (without starting the engine). Then check for fuel leaks at the hose connections.
- Start the engine and increase engine speed, verify that there are no fuel leaks.