Removal and Installation

FUEL TANK


Removal and Installation


REMOVAL

WARNING:
Be sure to read "General Precautions" when working on the fuel system. Refer to .
1. Drain fuel from fuel tank if necessary. Refer to Removal and Installation.

CAUTION:
- Because fuel tank becomes unstable when installing/removing, fuel should be drained if the level exceeds specification.
- Situate vehicle on a flat and solid surface.
2. Open fuel door and unscrew the fuel filler cap to release the pressure inside the fuel tank.
3. Release the fuel pressure from the fuel lines. Refer to For California MR20DE (California), Except For California MR20DE (except California), or Testing and Inspection QR25 DE.
4. Remove rear seat bottom. Refer to Component Parts Drawing 60/40 Split Fold Down Seat or Component Parts Drawing Fixed Back Seat.
5. Turn the three retainers (A) 90� in a clockwise direction and remove the fuel pump inspection hole cover.





6. Disconnect electrical connector (A) and fuel feed hose quick connector (B).
- Fuel feed hose (1)





- Disconnect the quick connector using the following procedure.
- Hold the sides of the connector, push in tabs and pull out the tube.





- If quick connector and tube on fuel pump assembly are stuck, push and pull several times until they move. Disconnect them by pulling.

CAUTION:
- The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.
- Do not use any tools to remove the quick connector.
- Keep resin tube away from heat. Be especially careful when welding near the resin tube.
- Prevent acid liquid such as battery electrolyte, from getting on resin tube.
- Do not bend or twist resin tube during installation and removal.





- To keep the connecting portion clean, free of foreign materials and to avoid damage, cover them completely with plastic bags or something similar.
- Do not insert plug to prevent damage to O-ring in quick connector.
7. Remove center exhaust tube. Refer to Component MR20DE, or Component QR25DE.
8. Remove fuel tank protector.





9. Loosen fuel filler hose clamp (B) and remove fuel filler hose (1).

CAUTION:
Do not remove fuel filler hose (1) from fuel filler tube. When removing fuel filler hose (1) at the fuel filler tube, mark components for alignment.
10. Remove vent hose (3) and EVAP hose (2) at rear of fuel tank.
- Disconnect vent hose and EVAP hose quick connectors using the following procedures.
a. Pinch retaining tabs (C) of vent hose quick connector and remove vent hose (3).
b. Pinch retaining tabs (A) of EVAP hose quick connector and remove EVAP hose (2).





- If hoses are stuck, push and pull (A) several times until they move freely, and disconnect by holding side of connector and pushing in the tabs (B).

CAUTION:
- The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.
- Do not use any tools to remove the quick connector.
- Keep the resin tube away from heat. Be especially careful when welding near the tube.
- Prevent acid liquid such as battery electrolyte, from getting on the resin tube.
- Do not bend or twist the tube during installation and removal.
- Do not insert plug that may cause damage to O-ring in quick connector.





- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
11. Support center of fuel tank (1) with transmission jack (A) as shown.






CAUTION:
Securely support the fuel tank with a suitable tool (B).
12. Remove fuel tank bands (RH and LH).
13. Lower transmission jack carefully to remove fuel tank while supporting it by hand as shown.

CAUTION:
Fuel tank may be in an unstable position because of the shape of fuel tank bottom. Be sure to support tank securely.

INSTALLATION
Installation is in the reverse order of removal.

EVAP Canister
1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a "click" sound is heard.
3. After connecting, make sure that the connection is secure.
- Pull the tube and the connector to make sure they are securely connected.

Fuel Tank Band
- Install them in the proper position by referring to the identification stamp mark "R" and "L" on the end.

Fuel Filler Hose
- Insert fuel filler hose (1) to the length (A) below on the fuel tank (3).






Fuel filler hose installation on fuel tank (A) : 35 mm (1.38 in)

- Be sure hose clamp (2) is not placed on swelled area of fuel filler hose (1).

EVAP Hose
1. Check connections for damage or foreign material.





2. Align the matching quick connector (A) with the center of EVAP hose (1), and insert quick connector (A) straight until it clicks.
3. After connecting, pull on quick connector (A) and EVAP hose (1) by hand. Make sure connections are secure.

INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch "ON" (without starting the engine), to check the connections for fuel leaks with the electric fuel pump applying pressure to the fuel piping.
2. Start the engine and let it idle to check that there are no fuel leaks at the fuel system connections.