Fuel Tank: Service and Repair
FUEL TANK
REMOVAL (VEHICLE NOT EQUIPPED WITH ORVR SYSTEM)
1) Relieve fuel pressure in fuel feed line according to procedure under Fuel Pressure Release.
2) Disconnect negative cable at battery.
3) Remove rear seat cushion.
4) Disconnect connectors of fuel tank wire harness.
5) Hoist vehicle.
6) Disconnect fuel tank filler hose and breather hose from filler neck.
7) As fuel tank has no drain plug, drain fuel tank by pumping fuel out through fuel tank filler or fuel tank inlet.
Use hand operated pump to drain fuel tank.
WARNING: Never drain or store fuel in an open container to avoid possibility of fire or explosion.
8) Disconnect fuel pipe joints and fuel hose from pipes.For quick joint, disconnect it as follows:
(1) Remove mud, dust and/or foreign material between pipe and joint by blowing compressed air.
(2) Unlock joint lock by inserting special tool between pipe and joint.
Special Tool
(A): 09919-47020
(3) Disconnect joint from pipe.
WARNING: A small amount of fuel may be released after fuel hose is disconnected. In order reduce the chance of personal injury, cover hose and pipe to be disconnected with a shop cloth. Be sure to put that cloth in an approved container when disconnection is completed.
9) Remove fuel tank from vehicle.
REMOVAL (VEHICLE EQUIPPED WITH ORVR SYSTEM)
1) Drain fuel from fuel tank as follows.
When vehicle fuel pump can be operated:
(1) Disconnect fuel return hose from fuel pressure regulator.
(2) Connect a proper size hose to fuel pressure regulator and insert the other end of hose into approved gasoline container.
(3) Drain fuel by operating fuel pump until fuel stops. Refer to step 6) of "Fuel Injector Inspection." (Fuel Injector/Testing and Inspection)
WARNING: Never drain or store fuel in an open container to avoid possibility of fire or explosion.
When vehicle fuel pump can not be operated:
(1) Remove fuel filler cap.
(2) Insert hose of a hand operated pump into fuel filler hose and drain fuel in space "A" in the figure (drain fuel through it till fuel stops). Do not force pump hose into fuel tank.
WARNING: Never drain or store fuel in an open container to avoid possibility of fire or explosion.
2) Relieve fuel pressure in fuel feed line according to procedure described under Fuel Pressure Release.
3) Disconnect negative cable at battery.
4) Remove rear seat cushion.
5) Disconnect connectors of fuel tank wire harness.
6) Hosit vehicle.
7) If fuel is drained by using vehicle fuel pump in step 1), disconnect fuel tank filler hose and pressure control valve hose from filler neck, and air suction outlet hose from its pipe.
If vehicle fuel pump can not be used to drain fuel in step 1), disconnect fuel tank filler hose from fuel tank, pressure control valve hose from filler neck, air suction outlet hose from its pipe and drain fuel from fuel tank as follows.
(1) Remove fuel tank inlet (check) valve from fuel tank.
(2) Insert hose of a hand operated pump into fuel tank inlet and drain remaining fuel with hand operated pump till fuel stops.
(3) Cover fuel tank inlet with moisture proof cloth adhesive tape or the like so as not to let fuel come out from it when removing fuel tank.
WARNING: Be sure to cover fuel tank inlet. Fuel may remain in space "B" in fuel tank even after fuel drainage procedure. Working on tank without covering its inlet may cause personal injury or fire.
8) Disconnect fuel pipe joints and fuel hose from pipes according to step 8) of "Fuel Tank Removal for Vehicle not Equipped with ORVR System".
9) Remove muffler mounting bolts and joint nuts, and then move muffler position to facilitate removal of fuel tank from vehicle body.
10) Support fuel tank with jack.
11) Remove fuel tank from vehicle body.
WARNING: Keep fuel tank horizontally and stably when removing it. Fuel may come out if tank is tilted. Also, fuel tank may drop and cause personal injury.
INSPECTION
After removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage. Also check for leaks from installation face of parts installed on fuel tank, visually inspect fuel tank for leaks and damage.
Replace any damaged or malconditioned parts.
FUEL TANK PURGING PROCEDURE
WARNING: This purging procedure will NOT remove all fuel vapor. Do not attempt any repair on tank using heat or flame as an explosion resulting in personal injury could occur.
Following procedure is used for purging fuel tank.
1) After removing fuel tank, remove all hoses, pipes, fuel pump and all other parts from fuel tank.
2) Drain all remaining fuel from tank.
3) Move tank to flushing area.
4) Fill tank with warm water or tap water, and agitate vigorously and drain. Repeat this washing until inside of tank is clean. Replace tank if its inside is rusty.
5) Completely flush out remaining water after washing.
CAUTION: Never leave water in fuel tank after washing, or inside of fuel tank will corrode.
INSTALLATION
1) If parts have been removed from top of fuel tank, install them according to the following procedure.
(1) Install fuel pump assembly to fuel tank referring to "Fuel Pump Assembly Service and Repair."
(2) Install tank pressure sensor, refuel vapor control valve, tank pressure control solenoid valve, EVAP canister and canister air valve to fuel tank if equipped.
(3) Install fuel pipes, hoses, tank pressure control valves and etc.
Clamp hoses and wire harness securely.
(4) Install fuel tank inlet valve to fuel tank inlet if equipped.
2) Install fuel tank and tank protector to vehicle.
3) Connect fuel filler hose and breather hose or pressure control valve hose to filler neck, and air suction outlet hose to its pipe if equipped.
4) Connect fuel hose and pipes to each pipe.
CAUTION: When connecting joint, clean outside surfaces of pipe inserted to joint, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.
Install muffler mounting bolts and joint nuts if removed.
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5) Connect connectors of fuel tank wire harness. Fix wire harness with tape as shown in figure.
6) Install rear seat cushion.
7) Connect negative cable to battery.
8) With engine "OFF" and ignition switch "ON", check for fuel leaks.