Fuel Tank: Service and Repair
Fuel Tank Assy Part 1:
Fuel Tank Assy Part 2:
Fuel Tank Assy Part 3:
Removal & Installation and Disassembly & Reassembly
1. REMOVE REAR SEAT CUSHION PAD
2. REMOVE REAR FLOOR SERVICE HOLE COVER
3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
4. DISCONNECT FUEL PUMP TUBE SUB-ASSY
5. REMOVE FUEL TANK VENT TUBE SET PLATE
6. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAUGE
7. DRAIN FUEL
8. REMOVE FLOOR PANEL BRACE REAR
9. REMOVE EXHAUST PIPE ASSY CENTER
10. DISCONNECT PARKING BRAKE CABLE ASSY NO.2
a. Remove the bolt and nut, and disconnect the parking brake cable.
11. DISCONNECT PARKING BRAKE CABLE ASSY NO.3
a. Remove the bolt and nut, and disconnect the parking brake cable.
12. REMOVE FUEL TANK PROTECTOR LOWER CENTER
a. Remove the 4 bolts and remove the protector.
13. DISCONNECT FUEL PUMP TUBE SUB-ASSY
a. Pinch the fuel pump tube connector clip and then pull out the tube.
NOTE:
- Check if there is any dirt like mud around the connector before this work and clean the dirt away.
- Be careful of dirt like mud because the quick connector has an O-ring to seal the pipe and the connector.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- After disconnecting the tube, cover the connector with a vinyl bag.
- When the connector and the pipe are stuck, pinch the tube between fingers, and turn it carefully to free and then disconnect the tube.
14. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
a. Disconnect the fuel tank to filler pipe hose from the fuel tank.
15. DISCONNECT FUEL TANK BREATHER HOSE
a. Disconnect the fuel tank breather hose from the fuel tank.
16. REMOVE FUEL TANK ASSY
a. Set the mission jack to the fuel tank.
b. Remove the fuel tank band.
c. Disconnect the valve to fuel filler pipe hose from the fuel tank over fill check valve.
d. Disconnect the fuel hose No.3 from the fuel tank.
e. Disconnect the vent line hose from the charcoal canister.
1. Push the connector deep inside.
2. Pinch portion A.
3. Pull out the connector.
f. Disconnect the fuel emission hose from the charcoal canister.
g. Carefully, remove the fuel tank assembly from the vehicle.
17. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSY
a. Using a screwdriver, unlock the claw and remove the protector by turning it counter clockwise.
b. Insert a clip remover between the check valve and the gasket, remove the valve by gradually pushing it upward.
NOTE:
- Work accurately to maintain the sealing performance of the check valve, since it is made from resin. It is easy to damage by removing and installing forcibly.
- Be sure to install new check valve and gasket.
18. REMOVE FUEL TANK PROTECTOR NO.3
a. Remove the fuel tank protector No.3 by sliding as shown in the illustration.
19. REMOVE FUEL TANK PROTECTOR SUB-ASSY NO.1
a. Remove the fuel tank protector No.1 by sliding as shown in the illustration.
20. REMOVE FUEL CUT OFF W/ TUBE VALVE ASSY
a. Using a screw driver, unlock the claw and remove the protector by turning it counter clockwise.
b. Insert a clip remover between the cut off valve and the gasket, remove the cut off valve by gradually pushing it upward.
NOTE:
- Work accurately to maintain the sealing performance of the cut off valve, since it is made from resin. It is easy to damage by removing and installing forcibly.
- Be sure to install new cut off valve and gasket.
21. REMOVE FUEL MAIN TUBE SUPPORT
22. REMOVE FUEL TANK CUSHION NO.1
23. REMOVE FUEL TANK CUSHION NO.2
24. INSTALL FUEL TANK CUSHION NO.1
a. Install the new fuel tank cushions as shown in the illustration.
25. INSTALL FUEL TANK CUSHION NO.2
a. Install the new fuel tank cushions as shown in the illustration.
26. INSTALL FUEL MAIN TUBE SUPPORT
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
27. INSTALL FUEL CUT OFF W/TUBE VALVE ASSY
a. Install a new gasket to the fuel tank.
b. Apply light oil around the new fuel cut off valve as shown in the illustration, and insert it into the tank without force. Be careful not to drop the gasket into the tank.
c. Check that the fuel cut off valve is fully inserted.
28. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSY
a. Install a new gasket to the fuel tank,
b. Apply light oil around the new check valve as shown in the illustration, and insert it into the tank without force. Be careful not to drop the gasket into the tank.
c. Check that the check valve is fully inserted.
29. INSTALL FUEL TANK ASSY
a. Set the mission lack to the fuel tank.
b. Install the fuel tank with the fuel tank bands.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
30. CONNECT FUEL PUMP TUBE SUB-ASSY
a. Push in the fuel tube connector to the fuel pipe until 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.
31. INSTALL FUEL TANK PROTECTOR LOWER CENTER
a. Install the protector with the 4 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
32. INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
33. INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
34. INSTALL EXHAUST PIPE ASSY CENTER
35. INSTALL FLOOR PANEL BRACE REAR
36. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAUGE
37. INSTALL FUEL TANK VENT TUBE SET PLATE
38. INSTALL FUEL PUMP TUBE SUB-ASSY
39. INSTALL REAR FLOOR SERVICE HOLE COVER
40. INSPECT FUEL LEAK
41. CHECK EXHAUST LEAKAGE