Fuel Tank: Service and Repair

WARNING: Be sure to read "WARNING" at the beginning of On-Vehicle Service and observe what is written there.

REMOVAL
1. Relieve fuel pressure in fuel feed line according to procedure described.
2. Disconnect negative cable at battery.






3. Remove rear seat cushion, rear right seat back, right side sill scuff, right front partition trim and right rear door opening trim.
4. Disconnect connectors of fuel tank wire harness.






5. Remove parking brake cover and console box.
6. Disconnect connector of heated oxygen sensor-2.






7. Hoist vehicle.
8. Remove muffler.






9. Disconnect connector from EVAP canister air valve.
10. Disconnect hoses from EVAP canister. For quick joint, disconnect it as follows:
1. Remove mud or dust around joint by blowing compressed air, and push joint fully in arrow direction.
2. Disconnect hose joint while joint lock is unlocked by pushing both sides of joint.






11. Disconnect fuel filler hose and pressure control valve hose from filler neck.
12. As fuel tank has no drain plug, drain fuel tank by pumping fuel out through fuel tank filler.

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.
- Do not force hose of a hand operated pump into or out of fuel tank. Doing so can damage inlet valve.






13. Disconnect fuel pipe joints 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 to 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.

14. Support fuel tank with jack.
15. Remove fuel tank from vehicle.

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.

The 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 Installation" in this section.
2. Install tank pressure sensor, refuel vapor control valve, tank pressure control solenoid valve and fuel cut valve to fuel tank. Refer to each applicable item in "Engine and Emission Control System" for installation procedure.






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.

2. Install fuel tank and tank protector to vehicle.
Tighten fuel tank bolts to specified torque.
3. Connect fuel filler hose and pressure control valve hose to filler neck.
4. Connect pipe joints 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.






5. Connect connector to EVAP canister air valve.
6. Connect refuel vapor control valve hose and purge hose to EVAP canister.
For quick joint, push joint into pipe till joint lock clicks.






7. Install muffler and tighten muffler nuts to specified torque referring to "Exhaust System".






8. Connect connector of heated oxygen sensor-2.
9. Install console box and parking brake cover.






10. Connect connectors of fuel tank wire harness.
11. Install right rear door opening trim, right front partition trim, right side sill scuff, rear seat back and rear seat cushion.
12. Connect negative cable at battery.
13. With engine "OFF" and ignition switch "ON", check for fuel leaks.
14. Start engine and check each joint of exhaust system for leakage.