Fuel Tank: Service and Repair

FUEL TANK

Exploded View

Exploded View FL-11:

Removal and Installation

REMOVAL

WARNING: Read "General Precautions" before working on the fuel system.
Refer to "General Precautions". Technician Safety Information

1. Disconnect the 12-volt battery negative terminal.




2. Check the fuel level with the vehicle on a level surface. If the fuel gauge indicates more than the level as shown (7/8 full), drain the fuel from the fuel tank until the fuel gauge indicates a level at or below as shown (7/8 full).
- In case the fuel pump does not operate, use the following procedure.

a. Insert fuel tubing of less than 25mm (0.98in) diameter into the fuel filler tube through the fuel filler opening to drain fuel from the fuel filler tube.
b. Disconnect the fuel filler hose from the fuel filler tube.
c. Insert fuel tubing into the fuel tank through the fuel filler hose to drain fuel from the fuel tank.
- As a guide, the fuel level reaches or is less than the level on the fuel gauge as shown, when approximately 10 l (2 5/8 US gal, 2 1/4 Imp gal) of fuel is drained from a full fuel tank.

3. Open the fuel filler cap to release the pressure inside the fuel tank.
4. Release fuel pressure from fuel line. Refer to Inspection.
5. Remove rear seat bottom.




6. Turn the four retainers 90° in a clockwise direction and remove the fuel pump inspection hole cover.




7. Disconnect the fuel level sensor, fuel filter, and fuel pump assembly electrical connector, EVAP hose quick connector, and fuel feed hose quick connector.

a. Disconnect the quick connectors as follows:
- Hold the sides of the connector, push in tabs and pull out the tube.
- If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling.

CAUTION:
- The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.
- Do not use any tools to remove the quick connector.
- Keep the resin tube away from heat. Be especially careful when welding near the tube.
- Prevent acid liquid such as battery electrolyte, from getting on the resin tube.
- Do not bend or twist the tube during installation and removal.
- Only when the tube is replaced, remove the remaining retainer on the tube or fuel level sensor, fuel filter, and fuel pump assembly.
- When the tube or fuel level sensor, fuel filter, and fuel pump assembly is replaced, also replace the retainer with a new one (green colored retainer).

- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.

8. Remove the front tube at center pipe.
9. Remove the front tube hanger.
10. Remove the tunnel stay.
11. Remove the center exhaust tube with muffler.
12. Remove the parking brake cable retainers and position the parking brake cables out of the way.
13. Remove the fuel tank protector.
14. Remove the stabilizer bar brackets and reposition the stabilizer bar.
15. Disconnect the return hose.
16. Remove the fuel filler hose hose at the fuel tank side.
17. Remove the fuel filler hose hose at the tube side.
18. Remove the evap cannister bolt.
19. Reposition the evap cannister.
20. Disconnect the fuel tank mounting straps while supporting the fuel tank.
21. Remove the fuel tank.
22. If replacing the fuel tank, remove the fuel level sensor, fuel filter and fuel pump assembly to transfer to the new fuel tank.

INSTALLATION
Install in the reverse order of removal paying attention to the following.

- Before tightening the fuel tank mounting straps, temporarily install the filler hose and the recirculation hose.
Tighten all fuel tank mounting strap bolts to specification, then tighten the hose clamps.




- Connect the quick connector as follows:
- Check the connection for damage or any foreign materials.
- Align the connector with the tube, then insert the connector straight into the tube until a click is heard.

- After the tube is connected, make sure the connection is secure by performing the following checks:
- Pull on the tube and the connector to make sure they are securely connected.




- Visually confirm that the two retainer tabs are connected to the quick connector.

Inspection

INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Check connections for leakage by applying fuel pressure to fuel piping. Refer to "Inspection".
2. Start engine and rev it up and make sure there are no fuel leaks at the fuel system tube and hose connections.