Fuel Tank: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER
5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
6. DRAIN FUEL
7. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the rear floor service hole cover.
8. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Disconnect the fuel sender gauge connector.
b. Remove the 5 bolts and fuel sender gauge.
c. Remove the fuel sender gauge from the fuel tank.
NOTE: Be careful not to bend the arm of the fuel sender gauge.
9. REMOVE FRONT EXHAUST PIPE ASSEMBLY
10. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
11. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
12. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
HINT: Removal procedure of the No. 1differential support protector is the same as that of the No. 2 differential support protector.
13. REMOVE REAR FLOOR SIDE MEMBER COVER LH
14. REMOVE REAR FLOOR SIDE MEMBER COVER RH
15. REMOVE REAR SUSPENSION MEMBER BRACE LH
a. Remove the 4 bolts and suspension member brace lower LH.
16. REMOVE REAR SUSPENSION MEMBER BRACE RH
a. Remove the 4 bolts and suspension member brace lower RH.
17. 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.
18. DISCONNECT FUEL TUBE SUB-ASSEMBLY
a. Disconnect the fuel tank return vent tube.
NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
- 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 after disconnecting the fuel pump tube.
- If the fuel tube connector and pipe are stuck, push and pull on them to release them.
b. Disconnect the fuel tank main tube.
NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
- 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 after disconnecting the fuel pump tube.
- If the fuel tube connector and pipe are stuck, push and pull on them to release them.
19. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
a. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
20. DISCONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY
a. Disconnect the fuel hose clamp.
b. Remove the clip and disconnect the No. 3 fuel hose sub-assembly.
21. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY
a. Disconnect the fuel tube clamp.
b. Disconnect the fuel tank to canister sub-assembly.
NOTE
- Remove any dirt and foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
- 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 after disconnecting the fuel pump tube.
- If the fuel tube connector and pipe are stuck, push and pull on them to release them.
22. REMOVE FUEL TANK ASSEMBLY
a. Place a engine lifter under the fuel tank assembly.
b. Remove the 4 bolts, fuel tank bands and fuel tank assembly.
23. REMOVE NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY
a. Remove the 4 bolts, No. 1 fuel tank breather tube sub-assembly and gasket.
24. REMOVE FUEL TUBE SUB-ASSEMBLY
a. Disconnect the clamp and remove the fuel tank main tube and fuel tank return vent tube.
b. Disconnect the 2 clamps and remove the edge protector.
25. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Loosen the hose clamp bolt and remove the fuel tank to filler pipe hose from the fuel tank.
26. REMOVE FUEL TANK VENT HOSE
a. Push the fuel tank vent hose deep into the fuel tank to release the lock pin.
b. Pinch portion A.
c. Pull out the fuel tank vent hose.
d. Remove the fuel vapor containment valve from the fuel tank.
27. REMOVE FUEL TANK CUSHION
a. Remove the 11 fuel tank cushions given in the illustration.
28. REMOVE NO. 2 FUEL TANK PROTECTOR
a. Remove the No. 2 fuel tank protector from the fuel tank assembly.
INSTALLATION
1. INSTALL NO. 2 FUEL TANK PROTECTOR
a. Install the No. 2 fuel tank protector to the fuel tank assembly.
2. INSTALL FUEL TANK CUSHION
a. Install 11 new fuel tank cushions given in the illustration.
3. INSTALL FUEL TANK VENT HOSE
a. Connect the fuel tank vent hose to the fuel tank.
4. INSTALL FUEL TANK TO FILLER PIPE HOSE
a. Install the fuel tank to filler pipe hose to the fuel tank with the clamp.
b. Tighten the hose clamp bolt.
5. INSTALL FUEL TUBE SUB-ASSEMBLY
a. Install the edge protector with the 2 clamps.
b. Install a fuel tank main tube and fuel tank return vent tube with the clamp.
6. INSTALL NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY
a. Install a new gasket to the No. 1 fuel tank breather tube sub-assembly.
b. Install the No. 1 fuel tank breather tube sub-assembly with the 4 bolts.
Torque: 1.5 N.m(15 kgf.cm, 13 in.lbf)
7. INSTALL FUEL TANK ASSEMBLY
a. Set a engine lifter 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)
8. CONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY
a. Connect the fuel tank to canister tube sub-assembly.
1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
NOTE
- Check for damage or foreign objects on the connected part.
- After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
9. CONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY
a. Connect the No. 3 fuel hose sub-assembly with the clip.
b. Connect the fuel hose clamp.
10. CONNECT FUEL TANK TO FILLER PIPE HOSE
a. Connect the fuel tank to filler pipe hose with the clamp.
11. CONNECT FUEL TUBE SUB-ASSEMBLY
a. Connect the fuel tank main tube.
1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
NOTE
- Check for damage or foreign objects on the connected part.
- After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
b. Connect the fuel tank return vent tube.
1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
NOTE
- Check for damage or foreign objects on the connected part.
- After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
12. 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 (194 kgf.cm, 14 ft.lbf) for bolt B
13. REMOVE REAR SUSPENSION MEMBER BRACE LH
a. Install the suspension member brace lower LH with the 4 bolts.
Torque: 19 N.m (195 kgf.cm, 14 ft.lbf)
14. REMOVE REAR SUSPENSION MEMBER BRACE RH
a. Install the suspension member brace lower RH with the 4 bolts.
Torque: 19 N.m (195 kgf.cm, 14 ft.lbf)
15. REMOVE REAR FLOOR SIDE MEMBER COVER LH
16. REMOVE REAR FLOOR SIDE MEMBER COVER RH
17. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
18. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
HINT: Installation procedure of the No. 1differential support protector is the same as that of the No. 2 differential support protector.
19. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
20. INSTALL FRONT EXHAUST PIPE ASSEMBLY
21. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Install the fuel sender gauge with the 5 bolts to the fuel tank.
Torque: 1.5 N.m(15 kgf.cm, 13 in.lbf)
b. Connect the fuel sender gauge connector.
22. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
23. ADD FUEL
24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
25. CHECK FOR FUEL LEAK
26. CHECK FOR EXHAUST GAS LEAK
27. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Install the service hole cover with new butyl tape.
28. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER
29. INSTALL REAR SEAT CUSHION ASSEMBLY
30. PERFORM INITIALIZATION
a. Perform initialization.
HINT: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.