Removal and Installation

Fuel System Components:

Removal
1. Relieve fuel pressure in fuel feed line referring to "Fuel Pressure Relief Procedure:".

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. Before disconnecting fuel filler hose, give match marks on fuel filler hose and fuel filler neck.
4. Disconnect fuel filler hose from fuel filler neck.
5. Insert hose of a hand operated pump into fuel filler hose (1) and drain fuel.

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




6. Remove fuel tank filler hose protector.
Disconnect filler hose (3) from fuel tank (1) and breather hose (2) from fuel filler neck.




7. Disconnect fuel filter inlet hose (3) from filter (1).




8. Disconnect fuel check valve hose (1) and return hose (2) and vapor control outlet hose (3) from pipes.
9. Remove fuel tank protector from vehicle.




10. Lower fuel tank gradually while holding it horizontally and pull out each coupler from fuel pump (1) and fuel tank pressure sensor (2).

Installation




1. Install fuel pump assembly, fuel cut valve and vapor control valve to fuel tank. Refer to "Fuel Pump Removal and Installation:"
2. Connect fuel hoses to fuel tank (1), fuel cut valve (15), and vapor control valve, check valve and fuel pump assembly (2).
After connecting, clamp hoses securely.
3. Install fuel tank by using fuel tank belts (10) and then install protector (9) to vehicle.

Tightening Torque
Fuel tank bolt (a): 50 N.m (5.0 kg.m, 36.5 lb.ft)
Fuel tank protector bolt (a): 50 N.m (5.0 kg.m, 36.5 lb.ft)

4. Connect fuel filler hose (13) to fuel filler neck (11) with match the match marks. And then clamp the securely.
5. Connect fuel filler hose to fuel tank and breather hose (5) to fuel filler neck. Clamp them securely.

Tightening Torque
Breather hose clamp (b): 2.0 N.m (0.2 kg.m, 2.0 lb.ft)
Fuel filler hose clamp (c): 4.0 N.m (0.4 kg.m, 3.0 lb.ft)

6. Install fuel filler hose protector.




7. Connect check valve hose (1), return hose (2) and vapor control valve outlet hose (3) to fuel pipe. And clamp them securely.




8. Connect fuel filter inlet hose (3) to fuel filter (1).
9. Connect coupler to fuel pump assembly and tank pressure sensor respectively.
10. Connect negative (-) cable to battery.
11. Upon completion of installation, check fuel system for leakage.