Fuel Tank: Service and Repair

Fuel Tank Assy:

Removal & Installation and Disassembly & Reassembly

1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE REAR SEAT CUSHION ASSEMBLY
3. REMOVE REAR FLOOR SERVICE HOLE COVER
4. REMOVE VAPOR PRESSURE SENSOR ASSEMBLY
5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
6. DISCONNECT FUEL EVAPORATION TUBE SUB-ASSEMBLY NO.2
7. REMOVE FUEL TANK VENT TUBE SET PLATE
8. REMOVE FUEL PUMP ASSEMBLY W/ FUEL SENDER GAGE ASSEMBLY
9. DRAIN FUEL
10. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (M/T TRANSAXLE)
11. REMOVE CONSOLE BOX SUB-ASSEMBLY REAR
12. REMOVE FLOOR PANEL BRACE FRONT
13. REMOVE EXHAUST PIPE ASSEMBLY FRONT

a. Remove the 2 heated oxygen sensor connectors.
b. Remove the grommet.
c. Remove the bolt and the clamp.
d. Remove the 2 bolts and 2 compression springs.

e. Disconnect the 2 exhaust pipe supports, and remove the exhaust pipe Assy front and gasket.

14. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.2

a. Remove the 2 set bolts of the parking brake cable.

15. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.3

a. Remove the 2 set bolts of the parking brake cable.

16. REMOVE FUEL TANK PROTECTOR NO.1

a. Remove the 3 clips and fuel tank protector lower center.

17. REMOVE FUEL TANK ASSEMBLY

a. Disconnect the fuel tank to filler pipe hose.

b. Disconnect the fuel vapor hose.

c. Disconnect the valve to fuel filler pipe hose.

d. Disconnect the fuel tank vent hose.
1. Deeply push the connector inside.
2. Pinch portion A.
3. Pull out the fuel tank vent hose.

e. Disconnect the fuel evaporation tube sub-assembly No. 2.
1. Pinch the fuel tube connector clip and then pull out the fuel emission tube.

NOTE:
- Check around the connector for dirt or mud before this operation and remove the dirt if necessary.
- Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release. Pull out the connector from the pipe.

f. Disconnect the fuel tank main tube sub-assembly

1. Pinch the tab of the retainer and rotate the tab to remove the lock claws and pull out the fuel pump tube.

g. Remove the fuel tank assembly.
1. Set a mission jack under the fuel tank.
2. Remove the 4 bolts and fuel tank.

18. REMOVE FUEL EVAPORATION TUBE SUB-ASSEMBLY NO.2

19. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
20. REMOVE CHECK VALVE PROTECTOR

a. Using a screwdriver, unlock the claw, and remove the check valve protector by turning it counterclockwise.

21. REMOVE FUEL TANK INLET VALVE ASSEMBLY

a. Insert a clip remover between the fuel tank inlet valve and gasket, remove the fuel tank inlet valve by gradually pushing it upward.

NOTE:
- Work accurately to maintain the sealing performance of the fuel tank inlet valve, since it is made from resin. It is easy to damage by removing and installing it forcibly.
- Be sure to install a new fuel tank inlet valve gasket.

22. REMOVE CHECK VALVE GASKET

a. Remove the gasket from the fuel tank inlet valve.

23. REMOVE FUEL TUBE CLAMP NO.1

24. REMOVE FUEL TUBE CLAMP NO.2

25. REMOVE FUEL TUBE CLAMP NO.3

26. REMOVE FUEL TANK SIDE PLATE
27. INSTALL CHECK VALVE GASKET

a. Install a new gasket to the fuel tank.

28. INSTALL FUEL TANK INLET VALVE ASSEMBLY

a. Apply a light coat of grease or gasoline around the fuel tank inlet valve as shown in the illustration. Insert insert it into the fuel tank without forcing it.

NOTE: Be careful not to drop the gasket into the tank.

29. INSTALL CHECK VALVE PROTECTOR
a. Install the check valve protector by turning it clockwise.
b. Lock the claw.

30. INSTALL FUEL TANK ASSEMBLY
a. Install the fuel tank assembly and 4 bolts.

Torque: 32 N.m (326 kgf.cm, 24 ft.lbf)

b. Connect the fuel tank main tube sub-assembly.
1. Push in the tube connector to the pipe and install the retainer.

NOTE:
- Check connected part for damage or foreign objects.
- After connecting, check if the fuel tube connector and pipe are securely connected by pulling on them.

c. Connect the fuel evaporation tube sub-assembly No. 2.
1. Push in the fuel tube connector to the pipe until the fuel tube connector makes a "click" sound.

NOTE:
- Check connected part for damage or foreign objects.
- After connecting, check if the fuel tube connector and pipe are securely connected by pulling on them.

d. Connect the fuel tank vent hose.
e. Connect the valve to fuel filler pipe hose.
f. Connect the fuel vapor hose.
g. Connect the fuel tank to filler pipe hose.

31. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.3

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

32. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.2

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

33. INSTALL EXHAUST PIPE ASSEMBLY FRONT

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

Minimum length: 40.5 mm (1.594 in.)

If the free length is not as specified, replace the compression spring.

b. Using a plastic hammer and wooden block, tap in a new gasket until its surface is flush with the exhaust manifold.

NOTE:
- Tap in the gasket in the correct direction.
- Do not reuse the removed gasket.
- Be sure not to push in the gasket when installing the exhaust pipe.

c. Install a new gasket to the exhaust pipe front.
d. Connect the 2 exhaust pipe supports, and install the exhaust pipe.

e. Install the clamp with the bolt as shown in the illustration.

Torque: 32 N.m (326 kgf.cm, 24 ft.lbf)

f. Install the 2 compression springs and 2 bolts.

Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)

g. Connect the 2 heated oxygen sensor connectors.
h. Install the grommet.

34. INSTALL FLOOR PANEL BRACE FRONT
35. INSTALL FUEL PUMP ASSEMBLY W/ FUEL SENDER GAGE ASSEMBLY
36. INSTALL FUEL TANK VENT TUBE SET PLATE
37. CONNECT FUEL EVAPORATION TUBE SUB-ASSEMBLY NO.2
38. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
39. INSTALL VAPOR PRESSURE SENSOR ASSEMBLY
40. INSTALL REAR FLOOR SERVICE HOLE COVER
41. ADD FUEL
42. CHECK FOR FUEL LEAKS
43. CHECK FOR EXHAUST GAS LEAKS