Fuel Tank: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTE:
- Some systems need to be initialized after the cable is reconnected.
- After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE FUEL TANK CAP
4. DISCONNECT FUEL TANK MAIN TUBE SUBASSEMBLY
a. Detach the lock claw by lifting up the cover, as shown in the illustration.
b. Pinch and pull the main tube connector to disconnect the connector from the pipe.
NOTE:
- Check for foreign matter in the pipe and around the connector. Clean if necessary.Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not forcefully bend or twist the nylon tube.
- Check for foreign matter on the pipe seal surface. Clean if necessary.
- Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
- If the pipe and connector are stuck together,pinch the connector between your fingers and turn it carefully to disconnect it.
5. DISCONNECT FUEL TANK RETURN TUBE
a. Detach the lock claw by lifting up the cover, as shown in the illustration.
b. Pinch and pull the return tube connector to disconnect the connector from the pipe.
NOTE:
- Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not forcefully bend or twist the nylon tube.
- Check for foreign matter on the pipe seal surface. Clean if necessary.
- Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
- If the pipe and connector are stuck together,pinch the connector between your fingers and turn it carefully to disconnect it.
6. DISCONNECT VENT LINE HOSE
a. Pull up the retainer and disconnect the vent line hose.
NOTE:
- Do not use any tools in this procedure.
- Check for any dirt and foreign matter contamination in the valve and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the valve and connector.
7. DISCONNECT WIRE HARNESS
a. Detach the harness clamp from the fuel tank.
8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
a. Detach the lock claw by lifting up the cover, as shown in the illustration.
b. Disconnect the fuel tank breather tube from the inlet pipe.
c. Disconnect the fuel tank to filler pipe hose from the inlet pipe.
d. Detach the filler pipe hose and breather tube from the No. 1 breather tube clamp.
9. DISCONNECT NO. 1 CANISTER OUTLET HOSE
a. Disconnect the canister outlet hose from the inlet pipe.
b. Detach the hose from the No. 1 breather tube clamp.
10. REMOVE FUEL TANK ASSEMBLY
a. Set a mission jack underneath the fuel tank.
b. Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.
c. Slowly lower the mission jack slightly.
NOTE: Be careful not to cut the wirings.
d. Detach the wire harness clamp from the fuel tank as shown in the illustration.
e. Disconnect the fuel pump connector and lower the mission jack.
NOTE:
- Before this procedure, check the connector for dirt, mud or other contamination.
- Do not use any tools in this procedure.
11. REMOVE FUEL TANK INLET PIPE SUB-ASSEMBLY
a. Remove the 2 nuts and inlet pipe.
12. REMOVE NO. 1 FUEL TANK HEAT INSULATOR
a. Remove the nut from the heat insulator.
b. Using needle-nose pliers, remove the 4 clips shown in the illustration and then remove the heat insulator.
13. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Remove the filler pipe hose from the fuel tank.
14. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
a. Remove the 2 tube joint clips and pull out the 2 fuel tank tubes.
NOTE:
- Remove any dirt and foreign matter on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
b. Using SST, loosen the retainer.
SST 09808-14020 (09808-01410, 09808-01420,09808-01430)
HINT: Fit the tips of SST onto the ribs of the retainer.
NOTE:
- When the retainer is loosened, be careful as the pump and gauge tube will spring upward from the force of the spring.
- Clean the pump and gauge tube before this operation.
c. Remove the retainer.
d. Remove the fuel suction with pump and gauge tube assembly from the fuel tank.
NOTE: Be careful not to bend the arm of the fuel sender gauge. (e) Remove the gasket from the fuel tank.
e. Remove the gasket from the fuel tank.
INSTALLATION
1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
a. Apply a light coat of gasoline or grease to a new gasket, and install it to the fuel tank.
b. Install the fuel suction with pump and gauge tube assembly into the fuel tank.
NOTE:
- Be careful not to bend the arm of the fuel sender gauge.
- Align the protrusion of the fuel suction with pump and gauge tube with the groove of the fuel tank.
c. Put the retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer one complete turn by hand.
d. Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank, as shown in the illustration.
SST 09808-14020 (09808-01410, 09808-01420,09808-01430)
HINT: Fit the tips of SST onto the ribs of the retainer.
e. Install the 2 fuel tank tubes with the 2 tube joint clips.
NOTE:
- Check that there are no scratches or foreign objects on the connecting parts.
- Check that the fuel tube joints are inserted securely.
- Check that the tube joint clips are on the collars of the fuel tube joints.
- After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
2. INSTALL FUEL TANK TO FILLER PIPE HOSE
a. Install the filler pipe hose to the fuel tank.
3. INSTALL NO. 1 FUEL TANK HEAT INSULATOR
a. Install the heat insulator with the 4 clips and nut.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
4. INSTALL FUEL TANK INLET PIPE SUB-ASSEMBLY
a. Install the inlet pipe with the 2 nuts.
Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
5. INSTALL FUEL TANK ASSEMBLY
a. Set the fuel tank on a mission jack and raise the fuel tank.
b. Connect the harness clamp and fuel pump connector to the fuel tank.
NOTE: Be careful not to cut the wirings.
c. Raise the mission jack.
d. Install the 2 fuel tank bands with the 2 pins and 2 clips.
e. Connect the 2 fuel tank bands with the 2 bolts.
Torque: 40 N.m (408 kgf.cm, 30 ft.lbf)
6. CONNECT NO. 1 CANISTER OUTLET HOSE
a. Connect the canister outlet hose to the inlet pipe.
b. Attach the hose to the No. 1 breather tube clamp.
7. CONNECT FUEL TANK TO FILLER PIPE HOSE
a. Connect the fuel tank to filler pipe hose to the inlet pipe.
b. Connect the fuel tank breather tube to the inlet pipe.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
c. Attach the lock claws to the connector by pushing down on the cover,as shown in the illustration.
d. Attach the filler pipe hose and breather tube to the No. 1 breather tube clamp.
8. CONNECT WIRE HARNESS
a. Attach the harness clamp to the fuel tank.
9. CONNECT VENT LINE HOSE
a. Connect the vent line hose and install the retainer.
NOTE:
- Check for damage or foreign objects on the connected part.
- After connecting, check that the vent hose and the valve are securely connected by pulling on them.
10. CONNECT FUEL TANK RETURN TUBE
a. Attach the lock claws to the connector by pushing down on the cover and connect the fuel tank return tube.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
b. Attach the lock claws to the connector by pushing down on the cover, as shown in the illustration.
11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Connect the fuel tank main tube.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
b. Attach the lock claws to the connector by pushing down on the cover, as shown in the illustration.
12. INSTALL FUEL TANK CAP
13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: Some systems need to be initialized after the cable is reconnected.
14. INSPECT FOR FUEL LEAK