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 ROOM NO. 3 PARTITION PAD
5. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER
6. REMOVE FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY
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 fuel return tube.
1. Remove the tube joint clip and fuel tube.
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 gauge retainer.
c. Hold SST with one hand and use SST, remove the fuel pump gauge retainer.
d. Remove the fuel return vent tube sub-assembly from the fuel tank.
NOTE: Be careful not to bend the arm of the sender gauge.
e. Remove the gasket.
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 FLOOR NO. 1 HEAT INSULATOR
a. Remove the 4 nuts and heat insulator.
12. REMOVE AIR GUIDE PLATE OUTSIDE RH
13. REMOVE REAR PROPELLER SHAFT ASSEMBLY (for 2WD)
14. REMOVE REAR PROPELLER SHAFT ASSEMBLY (for 4WD)
15. REMOVE NO. 2 FUEL TANK PROTECTOR
a. Remove the 4 nuts and fuel tank protector.
16. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
a. Remove the 2 nuts and differential support protector.
17. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
a. Remove the 2 nuts and differential support protector.
18. REMOVE REAR FLOOR SIDE MEMBER COVER LH
a. Remove the 2 bolts and member cover.
19. REMOVE REAR FLOOR SIDE MEMBER COVER RH
a. Remove the 2 bolts and member cover.
20. 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.
21. DISCONNECT FUEL TANK MAIN TUBE SUBASSEMBLY
a. Disconnect the fuel tank main tube RH.
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.
b. Disconnect the fuel tank main tube LH.
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.
22. DISCONNECT FUEL RETURN TUBE
a. Pinch and pull the return tube connector to disconnect the connector from the pipe.
23. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
a. Loosen the clamp and disconnect the filler pipe hose from the fuel tank filler pipe.
24. DISCONNECT FUEL EMISSION HOSE
a. Disconnect the fuel tank bracket hose.
b. Disconnect the 2 fuel emission hoses.
25. 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 bolts and 2 fuel tank bands.
26. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Detach the fuel tank main tube from the clamps, and remove it.
27. REMOVE FUEL RETURN TUBE
28. REMOVE FUEL TANK CUSHION
a. Remove the tank cushions and fuel tank brackets.
29. REMOVE NO. 1 FUEL TANK PROTECTOR
a. Remove the 2 nuts and fuel tank protector.
INSTALLATION
1. INSTALL NO. 1 FUEL TANK PROTECTOR
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 RETURN TUBE
4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Attach the fuel tank main tube to the clamps, and install it.
5. INSTALL FUEL TANK SUB-ASSEMBLY
a. Set the fuel tank on a mission jack, and raise the fuel tank.
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)
6. CONNECT FUEL EMISSION HOSE
a. Connect the 2 emission hoses.
b. Connect the fuel tank bracket hose.
7. CONNECT FUEL TANK TO FILLER PIPE HOSE
a. Tighten the clamp and connect the fuel tank to filler pipe hose.
8. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Connect the fuel tank main tube LH.
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. Connect the fuel tank main tube RH.
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.
9. CONNECT FUEL RETURN TUBE
a. Connect the fuel return tube and install the retainer.
10. CONNECT PARKING BRAKE CABLE ASSEMBLY
a. Connect the 4 clamps.
b. Connect the 2 parking brake cables with the 4 bolts.
Torque:
Bolt A 6.0 N.m (61 kgf.cm, 53 in.lbf)
Bolt B 19 N.m (193 kgf.cm, 14 ft.lbf)
11. INSTALL REAR FLOOR SIDE MEMBER COVER LH
a. Install the member cover with the 2 bolts.
12. INSTALL REAR FLOOR SIDE MEMBER COVER RH
a. Install the member cover with the 2 bolts.
13. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
a. Install the differential support protector with the 2 nuts.
14. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
a. Install the differential support protector with the 2 nuts.
15. 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)
16. INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 4WD)
17. INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 2WD)
18. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 4WD)
19. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 2WD)
20. INSTALL AIR GUIDE PLATE OUTSIDE RH
21. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR
a. Install the heat insulator with the 4 nuts.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
22. INSTALL FRONT FLOOR COVER CENTER RH
a. Attach the 2 clips, and install the floor cover center with the 3 nuts.
23. INSTALL EXHAUST PIPE ASSEMBLY
a. Install the exhaust pipe.
24. 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. Apply a light coat of gasoline to a new gasket, and set it to the fuel tank.
c. Set the fuel return vent tube sub-assembly to the fuel tank as shown in the illustration.
NOTE: Be careful not to bend the arm of the fuel sender gauge.
d. Align the protrusion of the fuel return vent tube subassembly and the cutout of the fuel tank.
e. While holding the fuel tube by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Then install the fuel pump gauge retainer to the fuel tank.
f. 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.
NOTE: Use SST. Do not any other tools such as a screwdriver.
g. Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that the starting mark on the retainer is within the indicated range in the illustration.
h. Connect the fuel return tube.
1. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
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.
25. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel sender gauge connector.
b. Install the service hole cover with new butyl tape.
26. INSTALL FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY
27. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
28. INSTALL ROOM NO. 3 PARTITION PAD
29. INSTALL REAR SEAT CUSHION ASSEMBLY
30. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
31. INSPECT FOR FUEL LEAK
32. INSPECT FOR EXHAUST GAS LEAK
33. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.