Fuel Tank: Service and Repair

REMOVAL
1) Relieve fuel pressure.

CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst.

2) Disconnect negative cable at battery.





3) For SE series vehicle, disconnect fuel level gauge, fuel pump and tank pressure sensor (EVAP-II vehicle) lead wire couplers and release harness clamp after removing rear bumper cover.





4) Remove fuel tank filler hose cover.
Then disconnect filler hose and breather hose from fuel tank.
5) Remove fuel tank inlet valve.
6) Due to absence of fuel tank drain plug, drain fuel tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.

CAUTION: Never drain or store fuel in an open container due to possibility of fire or explosion.





7) Disconnect fuel filter inlet pipe from filter.





8) Disconnect fuel vapor hose and return hose from pipes.
9) Remove fuel tank and protector from vehicle and for SZ series vehicle, disconnect fuel pump, fuel level gauge and tank pressure sensor (EVAP-II vehicle) lead wire couplers.

INSTALLATION





1) Install fuel pump, fuel level gauge, fuel cut valve (SE series 4 door or SZ series vehicle) and tank pressure sensor (EVAP-II vehicle) to fuel tank. Use new gaskets and 0-ring.
2) Install fuel separator, inlet valve and tank pressure control valve (SE series 2 door vehicle) to fuel tank directing tank pressure control valve black nozzle toward fuel separator.
3) Connect fuel hoses to fuel tank, fuel pump, tank pressure control valve and separator.
After connecting, clamp hoses securely.
4) Install fuel tank and cover to vehicle.
5) Connect fuel filler hose and breather hose to fuel filler neck. Clamp them securely.
6) Install fuel filler hose cover.





7) Connect fuel vapor hose and return hose to fuel pipe. Clamp them securely.
8) Connect fuel filter inlet pipe to fuel filter. Use new gaskets and tighten union bolt to specification.

Tightening Torque
(a): 35 Nm (3.5 kg-m, 25.5 lb-ft)





9) Connect fuel pump and level gauge couplers.
10) Install rear bumper cover.
11) Connect negative cable to battery.
12) Upon completion of installation, check fuel system for leakage.