Fuel Tank: Service and Repair

FUEL TANK

REMOVAL AND INSTALLATION

Pre-removal & Pre-installation Operation:

Removal Steps 1-12:

Removal Steps 13-32:

Removal Steps 33-40:

REMOVAL SERVICE POINTS

[[A]] FUEL PUMP MODULE CONNECTOR/FUEL TANK DIFFERENTIAL PRESSURE SENSOR CONNECTOR DISCONNECTION

1. Remove the rear seat cushion assembly (Refer to Interior, Rear Seat Assembly).




2. Remove the hole cover.




3. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector connection.

[[B]] FUEL LEVEL SENSOR (SUB) CONNECTOR DISCONNECTION




1. Remove the grommet.




2. Disconnect the fuel level sensor (sub) connector.

[[C]] FUEL HIGH-PRESSURE HOSE DISCONNECTION

CAUTION: As there will be some pressure remaining in the fuel pipe line, cover it with a shop towel to prevent fuel from spraying out.

[[D]] FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL

1. Support the fuel tank with a transaxle jack.
2. Remove the fuel tank band and fuel tank assembly as follows.




1. Remove the front securing nut of the fuel tank band.
2. Tilt the fuel tank assembly forward and lower it gradually to remove it.
3. Remove the fuel tank band.

[[E]] FUEL PUMP MODULE REMOVAL

CAUTION:
- When removing the fuel pump module from the fuel tank, be careful not to spill the fuel remaining in the fuel pump module.
- When withdrawing the fuel pump module from the fuel tank, be careful not to damage the module unit and the float.









1. Drain the fuel remaining in the fuel pump module while removing the fuel pump module from the service hole.
2. Disconnect the suction hose and remove the fuel pump module from the fuel tank.

[[F]] FUEL LEVEL SENSOR (SUB) REMOVAL






CAUTION: When withdrawing the fuel level sensor (sub) from the fuel tank, be careful not to damage the sensor unit and the float.

INSTALLATION SERVICE POINTS

]]A[[ FUEL LEVEL SENSOR (SUB) INSTALLATION






CAUTION: When inserting the fuel level sensor (sub) into the fuel tank, be careful not to damage the sensor unit and the float.

]]B[[ FUEL PUMP MODULE INSTALLATION






CAUTION:
- When installing the fuel pump module into the fuel tank, be careful not to damage the module unit and the float.
- Check the fuel lever sensor moving part of the fuel pump module works smoothly and then install the fuel pump module into the fuel tank.




1. Connect the suction hose to the fuel pump module.
2. Install the fuel pump module into the fuel tank.

]]C[[ FUEL HIGH-PRESSURE HOSE CONNECTION

CAUTION: After installing, slightly pull the fuel high-pressure hose and ensure that there is no disengaged fuel high-pressure hose. Also confirm that there is approximately 3 mm (0.12 inch) play at this time.

]]D[[ FUEL TANK ASSEMBLY/FUEL TANK BAND INSTALLATION
1. Raise the fuel tank assembly carefully with a transaxle jack.
2. Ensure that the fuel tank assembly does not interfere with surrounding parts. Then install the fuel tank band and tighten the mounting nuts to the specified torque.

Tightening torque: 26 ± 5 N.m (19 ± 4 ft-lb)

3. Again, ensure that the fuel tank assembly does not interfere with surrounding components. If the fuel tank assembly interferes surrounding components, remove the fuel tank assembly and the tank band and reinstall them.