Fuel Tank: Service and Repair
REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
3. REMOVE REAR SEAT CUSHION ASSY
4. REMOVE REAR FLOOR SERVICE HOLE COVER
5. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY
6. DRAIN FUEL
7. REMOVE FLOOR PANEL BRACE REAR
8. REMOVE EXHAUST PIPE ASSY CENTER
(a) Remove the 2 bolts and 4 nuts.
(b) Remove the exhaust pipe center and 2 gaskets from the 2 exhaust pipe supports.
9. DISCONNECT PARKING BRAKE CABLE ASSY NO.2
(a) Remove the bolt and nut, then disconnect the parking brake cable No.2.
10. DISCONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Remove the bolt and nut, then disconnect the parking brake cable No.3.
11. REMOVE FUEL TANK PROTECTOR LOWER CENTER
(a) Remove the 4 bolts, then remove the fuel tank protector lower center.
12. REMOVE FUEL TANK ASSY
(a) Disconnect the fuel pump tube.
(1) Pinch the projection of the retainer to remove the lock claws, then pull it down as shown in the illustration.
(2) Pull out the fuel pump tube.
NOTICE:
- Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
- Be careful of mud because the quick connector has an 0-ring which seals the pipe and quick connector that can be contaminated.
- Do not use any tools in this operation.
- Do not bend or twist the nylon tube. Protect the quick connector by covering it with a vinyl or plastic bag.
- When the pipe and quick connector are stuck, push and pull the quick connector to release. Pull out the quick connector from the pipe.
(b) Disconnect the fuel tube No.1.
(1) Pinch the tube connector, then pull out the fuel tube No.1.
NOTICE:
- Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
- Be careful of mud because the quick connector has an 0-ring which seals the pipe and quick connector that can be contaminated.
- Do not use any tools in this operation.
- Do not bend or twist the nylon tube. Protect the quick connector by covering it with a vinyl or plastic bag.
- When the pipe and quick connector are stuck, push and pull the quick connector to release. Pull out the quick connector carefully.
(c) Set up a transmission jack underneath the fuel tank.
(d) Remove the 2 bolts which hold the fuel tank bands.
(e) Loosen the clamp bolt.
(f) Operate the transmission jack, then disconnect the fuel tank inlet pipe.
(g) Disconnect the fuel tank vent hose from the charcoal canister.
(1) Deeply push the quick connector to release the lock pin.
(2) Pinch portion A.
(3) Pull out the fuel tank vent hose.
(h) Operate the transmission jack, then remove the fuel tank.
(i) Remove the 2 pins, then remove the 2 fuel tank bands as shown in the illustration.
(j) Remove the 4 clip nuts.
13. REMOVE FUEL TANK VENT HOSE
(a) Deeply push the quick connector to release the lock pin.
(b) Pinch portion A.
(c) Pull out the fuel tank vent hose.
14. REMOVE FUEL PUMP TUBE SUB-ASSY
(a) Remove the fuel pump tube from the fuel main tube sup- port.
15. REMOVE FUEL MAIN TUBE SUPPORT
(a) Remove the bolt, then remove the fuel main tube support.
16. REMOVE FUEL TANK CUSHION NO.2
(a) Remove the 7 fuel tank cushions from the fuel tank.
17. INSTALL FUEL TANK CUSHION NO.2
(a) Install 7 new fuel tank cushions to the fuel tank.
18. INSTALL FUEL MAIN TUBE SUPPORT
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
19. INSTALL FUEL PUMP TUBE SUB-ASSY
20. INSTALL FUEL TANK VENT HOSE
(a) Push in the quick connector to the pipe until the quick connector makes a "click" sound.
NOTICE:
- Check the connected part for damage or foreign objects.
- After connecting, check if the quick connector and pipe are securely connected by pulling on them.
21. INSTALL FUEL TANK ASSY
(a) Install the 4 clip nuts.
(b) Install the 2 fuel tank bands with the 2 pins.
(c) Set up the fuel tank to the transmission jack.
(d) Connect the fuel tank vent hose to the charcoal canister.
(1) Push in the quick connector to the pipe until the quick connector makes a "click" sound.
NOTICE:
- Check the connected part for damage or foreign objects.
- After connecting, check if the connector and pipe are securely connected by pulling on them.
(e) Operate the transmission jack, then connect the fuel tank filler pipe.
(f) Tighten the clamp bolt.
(g) Tighten the 2 bolts which hold the fuel tank bands.
Torque: 39 N-m (400 kgf-cm, 29 ft-lbf)
(h) Connect the fuel tube No.1.
(1) Push in the quick connector to the pipe until the quick connector makes a "click" sound.
NOTICE:
- Check the connected part for damage or foreign objects.
- After connecting, check if the quick connector and pipe are securely connected by pulling on them.
(i) Connect the fuel pump tube.
(1) Push in the quick connector to the pipe until the quick connector makes a "click" sound, then push up the retainer until the claws lock.
NOTICE:
- Check the connected part for damage or foreign objects.
- After connecting, check if the connector and pipe are securely connected by pulling on them.
22. INSTALL FUEL TANK PROTECTOR LOWER CENTER
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
23. INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
24. INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
25. INSTALL EXHAUST PIPE ASSY CENTER
(a) Install 2 new gaskets and the exhaust pipe center to the 2 exhaust pipe supports.
(b) Tighten the 2 bolts and 4 new nuts.
Torque: 56 N-m (571 kgf-cm, 41 ft-lbf)
26. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY
27. ADD FUEL
28. CONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
29. CHECK FOR FUEL LEAKS
30. CHECK FOR EXHAUST GAS LEAKS
31. INSTALL REAR FLOOR SERVICE HOLE COVER
32. INSTALL REAR SEAT CUSHION ASSY
33. INSTALL FLOOR PANEL BRACE REAR
34. SYSTEM INITIALIZATION