Fuel Tank Purging and Reinstallation

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 cut valves, fuel pump and fuel level gauge 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 remain water in fuel tank after washing, or fuel tank inside will get corrosion.

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".
2. Install tank pressure sensor, refuel vapor control 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. referring to figure in FUEL SYSTEM under GENERAL DESCRIPTION.
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 referring to figure under GENERAL DESCRIPTION.
3. Connect fuel filler hose and breather 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.




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




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.