Fuel Tank: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE NO. 3 ROOM PARTITION PAD
a. Remove the clip and room partition pad.
5. REMOVE REAR NO. 2 FLOOR SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the fuel pump connector.
6. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY
a. Disconnect the fuel main tubes and pump tube.
1. Remove the 2 tube joint clips and fuel 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. Loosen the fuel pump gauge retainer.
NOTE: Use SST. Do not use any other tools such as a screwdriver.
1. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
SST 09808-14020
HINT: Fit the tips of SST on the ribs of the retainer.
2. Using SST, loosen the fuel pump gauge retainer.
c. While holding the SST with one by hand, remove the fuel pump gauge retainer.
d. Disconnect the fuel suction tube.
e. Remove the fuel suction tube from the fuel tank.
NOTE:
- Make sure that the sender gauge arm does not bend.
- Do not damage the fuel sub-suction tube.
7. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the fuel sender gauge connector.
8. REMOVE FUEL RETURN VENT TUBE SUBASSEMBLY
a. Disconnect the 2 fuel pump tubes.
1. Remove the 2 tube joint clips and fuel pump 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. Loosen the fuel pump gauge retainer.
NOTE: Use SST. Do not use any other tools such as a screwdriver.
1. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
HINT: Fit the tips of SST on the ribs of the retainer.
SST 09808-14020
2. Using SST, loosen the fuel gauge retainer.
c. While holding the fuel suction tube by hand, remove the fuel pump gauge retainer.
d. Remove the fuel return vent tube from the fuel tank.
NOTE: Be careful not to bend the arm of the sender gauge.
e. Remove the No. 1 fuel suction tube set gasket from the fuel tank.
f. Disconnect the fuel sender gauge connector.
g. Press down on the sender gauge claw labeled A.
Then slide the sender gauge upward.
9. REMOVE EXHAUST PIPE ASSEMBLY
a. Remove the exhaust pipe.
10. REMOVE FRONT FLOOR COVER CENTER RH
a. Remove the 3 nuts, 2 clips and floor cover.
11. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR
a. Remove the 4 nuts and heat insulator.
12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
13. REMOVE NO. 2 FUEL TANK PROTECTOR
a. Remove the 4 nuts and fuel tank protector.
14. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
a. Remove the 4 nuts and differential support protector.
15. REMOVE NO.2 DIFFERENTIAL SUPPORT PROTECTOR
a. Remove the 4 nuts and differential support protector.
16. REMOVE REAR FLOOR SIDE MEMBER COVER LH
a. Remove the 2 bolts and member cover.
17. REMOVE REAR FLOOR SIDE MEMBER COVER RH
a. Remove the 2 bolts and member cover.
18. DISCONNECT PARKING BRAKE CABLE ASSEMBLY
a. Remove the 2 parking brake cables from the 4 clamps.
b. Remove the 4 bolts and disconnect the 2 parking brake cables.
19. DISCONNECT FUEL TANK MAIN TUBE SUBASSEMBLY
NOTE:
- Check for any dirt and foreign matter contamination 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 any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
a. Pinch and pull the main tube connector to disconnect the connector from the pipe.
20. DISCONNECT FUEL RETURN TUBE
a. Pinch and pull the return tube connector to disconnect the connector from the pipe.
21. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
a. Disconnect the filler pipe hose from the fuel tank filler pipe.
22. REMOVE FUEL EMISSION HOSE
a. Disconnect the fuel tank bracket hose.
b. Disconnect the 2 fuel emission hoses.
23. REMOVE FUEL TANK SUB-ASSEMBLY
a. Remove the 2 nuts from the fuel tank.
b. Place a mission jack under the fuel tank.
c. Remove the 4 nuts and 2 fuel tank bands.
d. Remove the 2 nuts.
24. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY
a. Remove the 4 clamps, fuel pump tube and fuel main tube.
25. REMOVE FUEL TANK CUSHION
a. Remove the tank cushions and fuel tank brackets.
26. REMOVE NO. 1 FUEL TANK PROTECTOR
a. Remove the 2 nuts and fuel tank protector.
INSTALLATION
1. INSTALL NO. 1 FUEL TANK PROTECTOR SUBASSEMBLY
a. Install the tank protector with the 2 nuts.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
2. INSTALL FUEL TANK CUSHION
a. Install the tank cushions and tank brackets.
3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY
a. Install the fuel pump tube to the 4 clamps.
4. INSTALL FUEL TANK SUB-ASSEMBLY
a. Set a mission jack to the fuel tank and lift it up.
b. Install the 2 fuel tank bands with the 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
c. Install the 2 nuts.
Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
5. CONNECT EMISSION HOSE
a. Connect the 2 emission hoses.
6. CONNECT FUEL TANK TO FILLER PIPE HOSE
a. Connect the fuel tank to filler pipe hose with the clamp.
7. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Connect the fuel pump tube connector.
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. Install the fuel hose connector cover to the pipe.
8. CONNECT FUEL RETURN TUBE
a. Connect the fuel return tube and install the retainer.
9. CONNECT PARKING BRAKE CABLE ASSEMBLY
a. Connect the 4 clamps.
b. Connect the 2 parking brake cables with the 4 bolts.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) for bolt A
19 N.m (193 kgf.cm, 14 ft.lbf) for bolt B
10. INSTALL REAR FLOOR SIDE MEMBER COVER LH
a. Install the member cover with the 2 bolts.
11. INSTALL REAR FLOOR SIDE MEMBER COVER RH
a. Install the member cover with the 2 bolts.
12. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
a. Install the differential supporter with the 2 nuts.
13. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
a. Install the differential supporter with the 2 nuts.
14. INSTALL NO. 2 FUEL TANK PROTECTOR
a. Install the tank protector with the 4 nuts.
Torque: 5.0 N.m (51 kgf.cm, 48 in.lbf)
15. ADJUST PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
16. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR
a. Install the heat insulator with the 4 nuts.
17. INSTALL FRONT FLOOR COVER CENTER RH
a. Install the floor cover center with the 3 nuts.
18. INSTALL EXHAUST PIPE ASSEMBLY
a. Install the exhaust pipe.
19. INSTALL FUEL RETURN VENT TUBE SUBASSEMBLY
a. Install the fuel sender gauge.
1. Set the fuel sender gauge to the fuel vent tube. Then slide the sender gauge downward to install it.
2. Connect the fuel sender gauge connector.
b. Set the fuel return vent tube to the fuel tank.
c. Apply a light coat of gasoline to a new gasket, and set it to the fuel tank.
d. Connect the fuel tube connector, and set the fuel suction with pump and gauge.
NOTE:
- Be careful not to bend the arm of the fuel sender gauge.
- When connecting the fuel tube connector, do not forcibly pull the tube.
e. Align the protrusion of the fuel suction tube and the cutout of the fuel tank.
f. While holding the fuel suction tube by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Install the fuel pump retainer to the fuel tank.
g. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
SST 09808-14020
HINT: Fit the rib on the fuel pump gauge retainer into the cutout of SST.
NOTE: Use SST. Do not any other tools such as a screwdriver.
h. Hold SST with one hand use SST to tighten the fuel pump gauge retainer 2 turns so that that the starting mark on the retainer is within the in the indicated range in the illustration.
i. Connect the fuel return tube and pump tube.
1. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
j. Connect the fuel suction tube connector.
NOTE:
- Check that there are no scratches or foreign matter around the connected parts of the fuel tube joint and plug before performing this work.
- Check that the fuel tube joint is securely inserted.
- Check that the tube joint clip is on the collar of the fuel tube joint.
- After installing the tube joint clip, check that the fuel tube cannot be pulled out.
20. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel sender gauge connector.
b. Install the service hole cover with new butyl tape.
21. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
22. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel pump connector.
b. Install the service hole cover with new butyl tape.
23. INSTALL NO. 3 ROOM PARTITION PAD
a. Install the partition pad with the clip.
24. INSTALL REAR SEAT CUSHION ASSEMBLY
25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
26. CHECK FOR FUEL LEAKS
27. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.