Fuel Tank: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. 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.
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE REAR SEAT CUSHION SUPPORT BRACKET
5. REMOVE REAR FLOOR SERVICE HOLE COVER
6. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY
7. REMOVE NO. 2 FUEL EVAPORATION TUBE SUBASSEMBLY
8. REMOVE EXHAUST PIPE ASSEMBLY
a. Remove the exhaust pipe assembly.
9. DRAIN FUEL
10. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY
a. Remove the 2 bolts and disconnect the cable clamp as shown in illustration A given.
11. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY
a. Remove the 2 bolts and disconnect the cable clamp as shown in illustration B given.
12. REMOVE NO. 1 FUEL TANK PROTECTOR
a. Remove the 2 clips, fuel tank protector bracket and protector as shown in illustration G given.
13. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel tank to filler pipe hose from the fuel tank as shown in illustration C given.
b. Disconnect the fuel vapor hose from the fuel tank as shown in illustration C given.
c. Disconnect the fuel tank vent hose from the canister as shown in illustration D given.
HINT: Pull up the retainer and pull out the vent hose.
d. Disconnect the fuel pump tube as shown in illustration E given.
1. Disengage the lock claw by lifting up the checker, as shown in the illustration.
2. Check for dirt or mud on the pipe and around the connector before disconnection. Clean as necessary.
3. Disconnect the connector and pipe by hand.
4. If the connector and the pipe are stuck, pinch the connector, and push and pull the pipe to disconnect it.
NOTE: Do not use any tools.
5. Check for dirt or mud on the seal surface of the disconnected pipe. Clean as necessary.
6. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
e. Remove the 4 bolts and fuel tank as shown in illustration A, B, C and F given.
14. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY
a. Remove the tube joint clip, and then pull out the pump tube.
15. REMOVE NO. 2 FUEL EVAPORATION TUBE SUBASSEMBLY
a. Pinch the No. 2 fuel evaporation tube clip, and then pull out the No. 2 fuel evaporation tube.
16. REMOVE NO. 3 FUEL TUBE CLAMP
a. Detach the 2 claws and remove the clamp.
17. REMOVE CHECK VALVE PROTECTOR
a. Remove the 3 bolts and protector.
18. REMOVE NO. 2 FUEL EVAPORATION TUBE SUBASSEMBLY
a. Pinch the tube connector clip, and then pull out the evaporation tube.
19. REMOVE FUEL TANK VENT HOSE
a. Pull up the retainer and pull out the vent hose.
20. REMOVE CHECK VALVE SUPPORT
a. Remove the 3 bolts and valve support.
21. REMOVE FUEL TANK INLET VALVE ASSEMBLY
a. Remove the inlet valve from the fuel tank.
22. REMOVE NO. 1 FUEL TUBE CLAMP
a. Detach the 2 claws and remove the clamp.
23. REMOVE FUEL TANK SIDE PLATE
a. Remove the side 4 plates from the fuel tank.
24. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Loosen the clamp.
b. Remove the hose from the fuel tank inlet pipe.
INSTALLATION
1. INSTALL FUEL TANK SIDE PLATE
a. Install the side 4 plates to the fuel tank.
2. INSTALL NO. 1 FUEL TUBE CLAMP
a. Attach the clamp to the fuel tank.
3. INSTALL FUEL TANK INLET VALVE ASSEMBLY
a. Install a new gasket and the inlet valve to the fuel tank.
NOTE: When removing or installing the fuel tank inlet valve, be careful as it is made from resin and will be easily damaged.
4. INSTALL CHECK VALVE SUPPORT
a. Install the valve support with the 3 bolts as shown in the illustration.
Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)
HINT:
- Angle of A: Approximately 20 degrees
- Angle of B: Approximately 25 degrees
5. INSTALL FUEL TANK VENT HOSE
a. Pull up the retainer and install the vent hose.
b. Connect the retainer.
6. INSTALL NO. 2 FUEL EVAPORATION TUBE SUBASSEMBLY
a. Install the No. 2 fuel evaporation tube.
7. INSTALL CHECK VALVE PROTECTOR
a. Install the protector with the 3 bolts.
Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)
8. INSTALL NO. 3 FUEL TUBE CLAMP
a. Attach the clamp to the fuel tank.
9. INSTALL FUEL PUMP ASSEMBLY WITH FUEL SENDER GAUGE ASSEMBLY
10. CONNECT NO. 2 FUEL EVAPORATION TUBE SUBASSEMBLY
11. INSTALL FUEL TANK VENT TUBE SET PLATE BOLT
12. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY
13. INSTALL FUEL TANK ASSEMBLY
a. Install the fuel tank with the 4 bolts as shown in A, B, C and F in the illustration given.
Torque: 14.3 N.m (146 kgf.cm, 11 ft.lbf)
b. Connect the fuel pump tube as shown in illustration E given.
1. Check that there is no damage or contamination in the connected part of the pipe.
2. Align the axis of the connector with the axis of the pipe, and push the pipe into the connector until the connector makes a "click" sound. if the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe.
3. After having finished the connection, try to pull apart the pipe and the connector, and confirm that they are securely connected.
4. Attach the lock claws to the connector by pushing down on the checker, as given in the illustration.
c. Connect the fuel tank vent hose to the canister as given in illustration D.
HINT: Pull up the retainer and install the vent hose, and then connect the retainer.
d. Connect the fuel vapor hose to the fuel tank as given in illustration C.
e. Connect a new fuel tank to filler pipe hose to the fuel tank and fuel inlet pipe as given in illustration C.
1. Tighten the 2 clamps of the fuel tank to filler pipe hose as given in the illustration.
14. INSTALL NO. 1 FUEL TANK PROTECTOR
a. Install the protector with the 2 clamps and fuel tank protector bracket as given in illustration G.
15. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY
a. Connect the 2 cable clamps with the 2 bolts as given in illustration B.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
16. CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY
a. Connect the 2 cable clamps with the 2 bolts as given in illustration A.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
17. INSTALL EXHAUST PIPE ASSEMBLY
a. Install the exhaust pipe.
18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
19. ADD FUEL
20. CHECK FOR FUEL LEAKS
21. INSTALL REAR FLOOR SERVICE HOLE COVER
22. INSTALL REAR SEAT CUSHION SUPPORT BRACKET SUB-ASSEMBLY
23. INSTALL REAR SEAT CUSHION ASSEMBLY
24. CHECK FOR EXHAUST GAS LEAKS