Fuel Tank: Service and Repair
REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear floor carpet assembly.
b. Remove the 3 screws and rear floor service hole cover.
c. Disconnect the connector.
3. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
a. Disconnect the fuel tank to filler pipe hose from the fuel filler pipe.
4. DRAIN FUEL
5. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1
a. Set a transmission jack to the fuel tank protector.
b. Remove the 6 bolts and the fuel tank protector.
6. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Pinch and turn the projections of the retainers in the direction shown by the arrow to release the lock. Pull out the 2 fuel tank tubes.
NOTE:
- Check that there is no dirt or mud around the quick connector before this work. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- To protect the tube, cover it with a plastic bag after checking.
- When the connector and the pipe are stuck, turn the retainer carefully to release. Disconnect the fuel tank tube.
7. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY
a. Pinch and turn the projection of the retainer in the direction shown by the arrow to release the lock. Pull out the fuel tank breather tube.
NOTE:
- Check that there is no dirt or mud around the quick connector before this work. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- To protect the tube, cover it with a plastic bag after checking.
- When the connector and the pipe are stuck, turn the retainer carefully to release. Disconnect the tube.
8. DISCONNECT FUEL TANK VENT HOSE
a. Disconnect the fuel tank breather tube from the fuel tank.
1. Push the connector deep inside.
2. Pinch portion A.
3. Pull out the connector.
9. REMOVE FUEL TANK ASSEMBLY
a. Set a transmission jack to the fuel tank.
b. Remove the 2 bolts, 2 fuel tank bands and fuel tank.
10. REMOVE FUEL TANK CUSHION
11. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Remove the 2 clips, and pull out the 2 fuel tank tubes.
NOTE:
- Check that there is no dirt or mud around the quick connector before this work. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- After disconnecting, cover the fuel tube joint with a plastic bag.
- When the fuel tube joint and fuel suction plate are stuck, turn the fuel tank main tube carefully to release and disconnect it. Likewise, disconnect the fuel tank return tube.
12. REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSEMBLY
NOTE: Protect a connector and tube joint with masking tape something in order to prevent sticking foreign objects onto them, and clean dirt and foreign objects from the fuel suction tube assembly before removing it.
a. Using SST, loosen the retainer.
SST 09808-14020 (09808-01410, 09808-01430)
HINT: A rib on the retainer can be fitted into the tip of SST.
b. Remove the retainer.
c. Remove the fuel suction w/ pump & gage tube assembly.
NOTE: Be careful not to bend the arm of the sender gage.
d. Remove the gasket from the fuel tank.
13. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY
a. Pinch and turn the projection of the retainer in the direction shown by the arrow to release the lock. Pull out the fuel tank breather tube.
NOTE:
- Check that there is no dirt or mud around the quick connector before this work. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- To protect the tube, cover it with a plastic bag after checking.
- When the connector and the pipe are stuck, turn the fuel tank breather tube carefully to release. Disconnect the tube.
14. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Remove the fuel tank to filler pipe hose from the fuel tank.
15. CONNECT FUEL TANK TO FILLER PIPE HOSE
a. Connect a new fuel tank to filler pipe hose to the fuel tank.
HINT: Make sure that the hose and tank are connected as shown in the illustration.
16. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY
a. Push in the tube connector to the pipe until the connector makes a "click" sound.
NOTE:
- Check if there is any damage or foreign objects on the connected part of the pipe.
- After connecting, check if the pipe and the connector are securely connected by pulling them.
17. INSTALL FUEL SUCTION W/PUMP & GAGE TUBE ASSEMBLY
a. Install a new gasket onto the fuel tank.
b. Set the fuel suction w/ pump & gage tube assembly to the fuel tank.
NOTE: Be careful not to bend the arm of the fuel sender gage.
c. Fit the spline of the fuel suction w/ pump & gage tube assembly into the keyway of the fuel tank.
d. Install the retainer.
1. Using a new retainer, align the mark on the retainer with the screw-thread starting point of the fuel tank.
2. While holding the fuel suction w/ pump & gage tube assembly, tighten the retainer one complete turn by hand.
e. Using SST, tighten the retainer one more complete turn, and position the mark on the retainer into range A of the fuel tank.
SST 09808-14020 (09808-01410, 09808-01430)
HINT:
- Turn the retainer two complete turns and position the mark within range A to install the retainer.
- A rib on the retainer can be fitted into the tip of SST.
18. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Connect the 2 fuel tank tubes with the 2 clips.
NOTE:
- Check that there is no scratch or foreign objects on the connecting parts.
- Check that the connector is fully inserted.
- Check that the tube joint clip is on the collar of the connector.
- After installing the tube joint clip, check if the tubes are securely connected by puling then.
19. INSTALL FUEL TANK CUSHION
a. Install 3 new fuel tank cushions to the fuel tank.
20. INSTALL FUEL TANK ASSEMBLY
a. Set a transmission jack to the fuel tank.
b. Install the fuel tank and 2 fuel tank bands with the 2 bolts.
Torque: 40 Nm (408 kgf.cm, 30 ft.lbf)
21. CONNECT FUEL TANK BREATHER TUBE SUB ASSEMBLY
a. Push in the tube connector to the pipe until the connector makes a "click" sound.
NOTE:
- Check that there is no damage or foreign objects the connected part of the pipe.
- After connecting, check if the pipe and the connector are securely connected by pulling them.
22. CONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Push in the tube connector to the pipe until the connector makes a "click" sound.
NOTE:
- Check that there is no damage or foreign objects the connected part of the pipe.
- After connecting, check if the pipe and the connector are securely connected by pulling them.
23. INSTALL FUEL TANK PROTECTOR SUB ASSEMBLY NO.1
a. Set a transmission jack to the fuel tank protector.
b. Install the fuel tank protector with the 6 bolts.
Torque: 20 Nm (204 kgf.cm, 15 ft.lbf)
24. INSTALL FUEL TANK TO FILLER PIPE HOSE
a. Install the fuel tank to filler pipe hose to the fuel filler pipe.
HINT: Make sure that the hose and pipe are connected as shown in the illustration.
25. CHECK FUEL LEAK
26. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the connector.
b. Install the 3 screws and rear floor service hole cover.
c. Install the rear floor carpet assembly.