Fuel Tank: Service and Repair
REPLACEMENT1. 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. DRAIN FUEL
4. REMOVE REAR SEAT CUSHION ASSY
5. REMOVE REAR FLOOR SERVICE HOLE COVER NO.2
a. Remove the 3 cap nuts and service hole cover.
6. REMOVE FUEL PUMP TUBE SUB-ASSY
NOTE:
- These procedures should be performed with the fuel tank less than 1/4 full.
- Check for dirt and 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 in these procedures.
- Do not forcefully bend or twist the nylon tube.
- Check for 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 and foreign matter.
- If the pipe and connector are stuck together, pinch the tube and turn it carefully to free it. Then disconnect the tube.
a. Disconnect the fuel tank side connector.
1. Remove the tube joint clip.
2. Pull out the fuel pump tube.
3. Plug the port of the fuel suction plate with a clean rubber cap.
b. Disconnect the fuel pipe side connector.
1. Clean the pipe.
2. Hold the claw of the retainer with your thumb and pull out the connector.
NOTE:
- If the connector and pipe are stuck together, release them by pushing and pulling them with hands.
- Do not reuse the retainer.
c. Protect each connecting part from damage and dirt by covering it with a plastic bag.
7. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the fuel sender gauge connector.
8. REMOVE FRONT FLOOR BRACE CENTER
9. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER RH
10. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER LH
11. REMOVE ENGINE UNDER COVER
12. REMOVE EXHAUST PIPE ASSY
13. REMOVE FRONT FLOOR HEAT INSULATOR NO.1
a. Remove the 4 bolts and heat insulator.
14. REMOVE PROPELLER SHAFT ASSY
15. REMOVE PARKING BRAKE CABLE ASSY NO.2
16. REMOVE PARKING BRAKE CABLE ASSY NO.3
17. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
18. DISCONNECT BREATHER TUBE FUEL HOSE
19. DISCONNECT FUEL HOSE SUB-ASSY NO.3
20. DISCONNECT FUEL TANK VENT HOSE
21. DISCONNECT FUEL CUT OFF W/TUBE VALVE ASSY
22. REMOVE FUEL TANK ASSY
a. Using a mission jack, support the fuel tank.
b. Disconnect the fuel tank band and remove the fuel tank.
23. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and set plate.
24. REMOVE FUEL PUMP AND SENDER GAUGE ASSY
a. Lift up the fuel pump and sender gauge, and disconnect the fuel sub-suction hose from the fuel return jet tube. Then remove the fuel pump, sender gauge and gasket.
NOTE:
- Be careful not to damage the fuel pump filter.
- Be careful not to bend the sender gauge arm.
25. REMOVE FUEL SENDER GAGE ASSY
a. Remove the 5 screws, sender gage and gasket.
26. REMOVE FUEL CUT OFF W/TUBE VALVE ASSY
a. Remove the valve and gasket.
27. REMOVE FUEL TANK PROTECTOR SUB-ASSY NO.1
28. REMOVE FUEL TANK CUSHION NO.1
29. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSY
NOTE:
- When installing or removing the check valve, do not use force. The check valve is made of resin and damages easily. Following these procedures carefully ensures that the check valve stays in good condition and maintains its sealing properties.
- Check valves and gaskets must be replaced with new ones.
a. Insert a clip remover between the check valve and the gasket, and remove the check valve by prying up the valve gradually.
30. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSY
a. Install a new gasket to the fuel tank.
b. Apply some gasoline to the entire circumference of a new over fill check valve, and insert it into the fuel tank.
NOTE:
- Do not insert the check valve with excessive force.
- Be careful not to drop the gasket into the tank.
- Make sure that there is no clearance between the gasket and the lower surface of the check valve.
31. INSTALL FUEL TANK CUSHION NO.1
a. Attach the fuel tank cushions to the shaded areas in the illustration.
32. INSTALL FUEL TANK PROTECTOR SUB-ASSY NO.1
33. INSTALL FUEL CUT OFF W/TUBE VALVE ASSY
a. Install a new gasket and the valve.
34. INSTALL FUEL SENDER GAGE ASSY
a. Install a new gasket and the sender gauge with the 5 screws.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
35. INSTALL FUEL PUMP AND SENDER GAUGE ASSY
a. Install a new gasket to the fuel suction plate.
b. Connect the fuel sub-suction hose to the fuel return jet tube.
c. Attach the fuel pump and sender gauge to the fuel tank.
36. INSTALL FUEL TANK VENT TUBE SET PLATE
a. Install the set plate with the 8 bolts.
Torque: 6.0 N.m (61 kgf.cm, 52 in.lbf)
37. INSTALL FUEL TANK ASSY
a. Securely place a mission jack under the fuel tank.
b. Jack up the fuel tank.
c. Install the fuel tank and fuel tank band with the 4 bolts.
Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf)
38. CONNECT FUEL CUT OFF W/TUBE VALVE ASSY
39. CONNECT FUEL TANK VENT HOSE
40. CONNECT FUEL HOSE SUB-ASSY NO.3
41. CONNECT BREATHER TUBE FUEL HOSE
42. CONNECT FUEL TANK TO FILLER PIPE HOSE
43. INSTALL PARKING BRAKE CABLE ASSY NO.3
44. INSTALL PARKING BRAKE CABLE ASSY NO.2
45. INSTALL PROPELLER SHAFT ASSY
46. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
a. Install the heat insulator with the 4 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
47. INSTALL EXHAUST PIPE ASSY
48. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER LH
49. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER RH
50. INSTALL FRONT FLOOR BRACE CENTER
51. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel sender gauge connector and install the service hole cover.
52. INSTALL FUEL PUMP TUBE SUB-ASSY
a. Connect the connector on the fuel tank side.
1. Attach the fuel tube connector to the fuel suction plate port.
2. Install the tube joint clip.
b. Connect the connector on the fuel pipe side.
1. Insert the connector by aligning the pipe and the connector until the retainer makes a "click" sound.
NOTE:
- Check for damage and foreign matter in the pipe and around the connector.
- After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart.
53. INSTALL REAR FLOOR SERVICE HOLE COVER NO.2
a. Install the service hole cover with the 3 nuts.
54. INSTALL REAR SEAT CUSHION ASSY
55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
56. PERFORM INITIALIZATION
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
57. ADD FUEL
58. CHECK FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS
59. CHECK FOR EXHAUST GAS LEAKS