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Fuel Tank: Service and Repair

Fuel Tank Assy Part 1:




Fuel Tank Assy Part 2:




Fuel Tank Assy Part 3:





FUEL TANK ASSEMBLY

Removal & Installation and Disassembly & Reassembly

NOTE: When disconnecting the battery terminal, initialize the following system after the terminal is reconnected.
- Power window control system
- Sliding roof system

1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE RR SEAT CUSHION ASSEMBLY
3. REMOVE REAR FLOOR SERVICE HOLE COVER
4. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY
5. DRAIN FUEL
6. REMOVE FLOOR PANEL BRACE FRONT




7. REMOVE EXHAUST PIPE ASSEMBLY CENTER
a. Remove the 4 bolts and 2 compression springs.
b. Remove the exhaust pipe center from the 2 exhaust pipe supports No. 4.




c. Remove the gasket from the exhaust pipe front.




d. Remove the gasket from the exhaust pipe center.




8. REMOVE FUEL TANK PROTECTOR NO.1
a. Remove the 5 bolts, then remove the fuel tank protector No.1.

9. REMOVE CHARCOAL CANISTER ASSEMBLY




10. REMOVE REAR SUSPENSION BRACE LOWER LH
a. Remove the 3 bolts, then remove the rear suspension brace lower.




11. REMOVE REAR SUSPENSION BRACE LOWER RH
a. Remove the 3 bolts, then remove the rear suspension brace lower.







12. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel tank main tube.
1. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and push it down as shown in the illustration.
2. Pull the fuel tank main tube out of the pipe.

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 the O-ring that seals 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 vinyl bag after disconnecting the fuel tank main tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.







b. Disconnect the fuel tank breather tube from the fuel tank.
1. Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.

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 the O-ring that the seals 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 vinyl bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.




c. Separate the claw fitting, then remove the fuel hose protector.




d. Loosen the hose clamp bolt, then disconnect the fuel tank to filler pipe hose.




e. Hold the fuel tank using a transmission jack.
f. Remove the 4 bolts, then remove the 2 fuel tank bands.
g. Operate the transmission jack, then remove the fuel tank.




13. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Remove the fuel tank main tube from the fuel tube clamp No. 3 and tank suction tube support.







14. REMOVE HOSE SUB-ASSEMBLY, FUEL TANK VENT
a. Remove the hose from the fuel tube clamp No.4.
b. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and slide it as shown in the illustration.
c. Pull the fuel tank vent hose out of the pipe.

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 the O-ring that seals 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 Vinyl bag after disconnecting the fuel tank vent hose.
- If the fuel tube connector and pipe are stuck, push and pull to release them.

15. REMOVE FLOOR WIRE NO.3




a. Remove the 3 wire harness clamps, then remove the floor wire No. 3.




b. Remove the wire harness clamp.
c. Separate the 2 claws fittings, then remove the fuel tank protector plate.




16. REMOVE TANK SUCTION TUBE SUPPORT
a. Separate the clip fittings, then remove the tank suction tube support.




17. REMOVE FUEL TUBE CLAMP NO.3
a. Separate the 2 clips fittings, then remove the fuel tube clamp No. 3.




18. REMOVE FUEL TUBE CLAMP NO.4
a. Remove the bolt, then remove the fuel tube clamp No. 4.




19. REMOVE FUEL TANK CUSHION NO.1
a. Remove the 10 fuel tank cushions No. 1 from the fuel tank.




20. INSTALL FUEL TANK CUSHION NO.1
a. Install 10 new fuel tank cushions No. 1 onto the fuel tank as shown in the illustration.




21. INSTALL FUEL TUBE CLAMP NO.4
a. Install the fuel tube clamp No. 4 with the bolt.

Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf)




22. INSTALL FUEL TUBE CLAMP NO.3
a. Align the clip positions, then install the fuel tube clamp No. 3.




23. INSTALL TANK SUCTION TUBE SUPPORT
a. Align the clip position, then install the tank suction tube support.




24. INSTALL FLOOR WIRE NO.3
a. Align the claws positions, then install the fuel tank protector plate.
b. Install the wire harness clamp.




c. Install the floor wire No. 3 with the 3 wire harness clamps.




25. INSTALL HOSE SUB-ASSEMBLY, FUEL TANK VENT
a. Align the fuel tube connector with the pipe, then push in the fuel tube connector until it comes into contact with the seat to connect the fuel tank vent hose to the pipe, then push the retainer up until to the claws lock.
b. Install the hose into the fuel Tube clamp No.4.

NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tube connector and pipe.




26. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Fit the fuel tank main tube into the fuel tube clamp No. 3 and tank suction tube support.




27. INSTALL FUEL TANK ASSEMBLY
a. Set the fuel tank onto a transmission jack.
b. Operate the transmission jack, then install the fuel tank into the vehicle.
c. Install the 2 fuel tank bands No. 1 with 4 bolts.

Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf)




d. Connect the fuel tank to filler pipe hose to the fuel tank, then tighten the hose clamp.

NOTE: Make sure that the mark and hose clamp are at the correct angle when installing.




e. Install the fuel hose protector.




f. Connect the fuel tank breather tube to the fuel tank.
1. Align the fuel tube connector with the pipe, then push the fuel tube connector until the retainer makes a "click" sound to connect the fuel tube breather tube to the pipe.

NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.




g. Connect the fuel tank main tube.
1. Align the fuel tube connector with the pipe, then push the fuel tube connector until the it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.

NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling the fuel tube connector and pipe.




28. INSTALL REAR SUSPENSION BRACE LOWER RH
a. Install the rear suspension brace lower.

Torque: 63.5 N.m (645 kgf.cm, 47 ft.lbf)




29. INSTALL REAR SUSPENSION BRACE LOWER LH
a. Install the rear suspension brace lower with 3 bolts.

Torque: 63.5 N.m (645 kgf.cm, 47 ft.lbf)

30. INSTALL CHARCOAL CANISTER ASSEMBLY




31. INSTALL FUEL TANK PROTECTOR NO.1
a. Install the fuel tank protector No. 1 with the 5 bolts.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

32. INSTALL EXHAUST PIPE ASSEMBLY CENTER




a. Check the free length.
1. Using vernier calipers, measure the free length of the compression spring.

Minimum: 38.5 mm (1.516 in.)

If the free length is less than minimum, replace the compression spring.




b. Using a wooden block and plastic-faced hammer, tap in a new gasket until it is flash with the exhaust pipe center.

NOTE:
- Make sure that the gasket is in the correct direction when installing.
- Do not reuse a removed gasket.
- Never push the gasket into the exhaust pipe center by installing the exhaust pipe center onto exhaust pipe tail.




c. Install a new gasket onto the exhaust pipe front.




d. Install the exhaust pipe center into the 2 exhaust pipe supports No. 4.
e. Tighten the 2 compression springs and 4 bolts.

Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)

33. ADD FUEL
34. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY
35. CONNECT BATTERY NEGATIVE TERMINAL

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

36. CHECK FOR FUEL LEAKAGE
37. CHECK FOR EXHAUST GAS LEAKAGE
38. INSTALL FLOOR PANEL BRACE FRONT
39. INSTALL REAR FLOOR SERVICE HOLE COVER
40. INSTALL RR SEAT CUSHION ASSEMBLY
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