Fuel Tank: Service and Repair
REMOVAL1. REMOVE REAR SEAT CUSHION ASSEMBLY
2. DISCHARGE FUEL SYSTEM PRESSURE
3. 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.
4. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER
5. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
NOTE:
- These procedures should be performed with the fuel tank less than 1/4 full.
- Check for dirt 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 in these procedures.
- Do not forcefully bend or twist the nylon tube.
- Check for dirt contamination on the pipe seal's 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. Disconnect the connector in the fuel tank side.
1. Remove the tube joint clip.
2. Pull out the fuel main tube.
3. Plug the port of the fuel suction plate with a clean rubber cap.
b. Disconnect the connector on the fuel pipe side.
1. Clean the pipe before the operation.
2. Pull out the connector, holding the claw of the retainer as given in the illustration.
NOTE: If the connector and the pipe are stuck together, release them by pushing and pulling them by hand.
HINT: Do not remove the retainer when it is reinstalled.
c. Protect each connecting part from damage and contamination by covering it with a plastic bag.
6. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the fuel sender gauge connector.
7. REMOVE FRONT FLOOR BRACE CENTER
8. REMOVE NO. 2 ENGINE UNDER COVER
9. REMOVE EXHAUST PIPE ASSEMBLY
a. Remove the exhaust pipe assembly.
10. REMOVE PROPELLER SHAFT HEAT INSULATOR
11. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR
a. Remove the 2 bolts and propeller shaft heat insulator.
12. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
13. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
14. REMOVE PROPELLER SHAFT ASSEMBLY
15. REMOVE NO. 2 PARKING BRAKE CABLE ASSEMBLY
16. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY
17. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Disconnect the air inlet hose from the filler pipe.
b. Disconnect the breather hose from the filler pipe.
c. Disconnect the fuel inlet tube from the filler pipe.
d. Remove the 2 bolts and filler pipe.
18. DISCONNECT VENT LINE HOSE
a. Disconnect the hose from the canister.
19. REMOVE FUEL TANK ASSEMBLY
a. Using a mission jack, support the fuel tank.
b. Remove the 4 bolts.
c. Disconnect the No. 1 fuel tank band and remove the fuel tank.
20. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and set plate.
21. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY
a. Lift up the fuel pump and sender gauge. Disconnect the fuel sub-suction hose from the fuel return jet tube, and remove the fuel pump, sender gauge and gasket.
NOTE:
- Do not damage the fuel pump filter.
- Be careful not to bend the arm of the sender gauge.
22. REMOVE FUEL SENDER GAUGE
a. Remove the 5 screws, sender gauge and gasket.
23. REMOVE NO. 1 FUEL TANK PROTECTOR SUBASSEMBLY
24. REMOVE FUEL TANK BREATHER TUBE SUBASSEMBLY
25. REMOVE VENT LINE HOSE
INSTALLATION
1. INSTALL NO. 1 FUEL TANK CUSHION
a. Attach the fuel tank cushions to the areas marked with diagonal lines in the illustration.
2. INSTALL FUEL SENDER GAUGE
a. Install a new gasket and the sender gauge to the fuel tank with the 5 screws.
Torque: 1.5 N.m(15 kgf.cm, 13 in.lbf)
3. INSTALL FUEL TANK BREATHER TUBE SUBASSEMBLY
a. Connect the breather tube to the fuel tank.
4. INSTALL VENT LINE HOSE
a. Connect the hose to the fuel tank.
5. CONNECT FUEL INLET TUBE
a. Connect the fuel inlet tube to the fuel tank.
6. INSTALL NO. 1 FUEL TANK PROTECTOR SUBASSEMBLY
7. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY
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.
8. 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)
9. INSTALL FUEL TANK ASSEMBLY
a. Install the fuel tank and fuel tank band with the 4 bolts.
Torque: 39 N.m(400 kgf.cm, 29 ft.lbf)
10. INSTALL FUEL TANK TO FILLER PIPE HOSE
a. Install the filler pipe with the 2 bolts.
b. Connect the air inlet tube to the filler pipe.
c. Connect the fuel inlet tube to the filler pipe.
d. Connect the breather tube to the filler pipe.
11. CONNECT VENT LINE HOSE
a. Connect the vent line hose to the canister.
12. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY
13. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY
14. INSTALL PROPELLER SHAFT ASSEMBLY
15. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
16. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
17. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR
a. Install the front floor heat insulator with the 4 bolts.
Torque: 5.4 N.m(55 kgf.cm, 47 in.lbf)
18. INSTALL PROPELLER SHAFT HEAT INSULATOR
19. INSTALL EXHAUST PIPE ASSEMBLY
a. Install the exhaust pipe assembly.
20. INSTALL NO. 2 ENGINE UNDER COVER
21. INSTALL FRONT FLOOR BRACE CENTER
22. INSTALL REAR FLOOR SERVICE HOLE COVER
23. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Connect the connector on the fuel tank side.
1. Attach the fuel tube connector to the port of the fuel suction plate.
2. Install the tube joint clip.
b. Connect the connector on the fuel pipe side.
1. Insert the connector by aligning the axes of the pipe and connector until the retainer makes a click sound.
NOTE:
- Check for damage and dirt contamination in the pipe and around the connector.
- After having finished the connection, check if the pipe and connector are securely connected by trying to pull them apart.
c. Connect the fuel pump connector.
24. ADD FUEL
25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
26. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
27. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAKS
28. CHECK FOR EXHAUST GAS LEAKS
29. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
30. INSTALL REAR SEAT CUSHION ASSEMBLY