Fuel Tank: Service and Repair
Fuel Tank Removal and Installation
Removal
1. Fuel Fill Cap
1. Remove the fuel fill cap to relieve the pressure in the fuel tank.
2. HDS DLC - Connection
1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
3. Fuel Pump Off
1. From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.
NOTE:
* Do not allow the engine to idle above 1,000 rpm or the PCM will continue to operate the fuel pump.
* Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.
2. Turn the ignition switch to LOCK (0).
4. Battery Terminal - Disconnection
1. Make sure the ignition switch is in LOCK (0).
2. Disconnect and isolate the negative cable (A) from the battery.
NOTE: Always disconnect the negative side first.
3. Disconnect the positive cable (B) from the battery.
5. Fuel Gauge Sending Unit Access Panel
1. Remove the access panel (A) from the floor.
2. Disconnect the connector (B).
6. Fuel Pressure - Relieving (Fuel Tank Unit)
NOTE: Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions. Service Precautions
1. Check the fuel quick-connect fitting for dirt, and clean it if needed.
2. Place a rag or shop towel (A) over the quick-connect fitting.
3. Disconnect the quick-connect fitting: Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.
NOTE:
* Be careful not to damage the line (D) or other parts.
* Do not use tools.
* If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily.
* Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
7. Fuel Tank Unit
1. Using the special tool, loosen the locknut (A).
2. Remove the locknut (A).
3. Remove the fuel tank unit (B).
8. Fuel Tank Draining
1. Using a hand pump, a hose, and a container suitable for fuel, drain the fuel from the fuel tank.
9. Vehicle Lift
1. Raise the vehicle on a lift, and make sure it is securely supported.
10. Rear Wheel
1. Remove the rear wheel.
11. Front Floor Undercover
1. Remove the bolts (A) and the clips (B, C) securing the front floor undercover (D), then remove the front floor undercover.
12. Middle Floor Undercover
Left side
Right side
1. Remove the bolts (A) and the clips (B, C), then remove the left middle floor undercover (D) or the right middle floor undercover (E).
13. Exhaust Pipe B
1. Remove the exhaust pipe B.
14. Propeller Shaft Protector No.1
1. Remove the No. 1 propeller shaft protector (A).
15. Propeller Shaft Protector No.2
1. Remove the No. 2 propeller shaft protector (A).
16. Propeller Shaft Transmission Side - Disconnection
1. Make reference mark (A) across the No. 1 propeller shaft (B) and the transfer companion flange (C).
2. Remove the No. 1 propeller shaft flange bolts (D).
17. Propeller Shaft Differential Side - Disconnection
1. Make reference mark (A) across the No. 2 propeller shaft (B) and the rear differential companion flange (C).
2. Remove the No. 2 propeller shaft flange bolts (D).
18. Propeller Shaft Assembly
1. Remove the center support bearing mounting bolts (A), then remove the propeller shaft assembly (B).
19. Fuel Tank Guard Pipe
1. Remove the fuel tank guard.
20. Fuel Tank Assembly
USA and Canada models
Mexico model
NOTE: Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions. Service Precautions
1. Disconnect the quick-connect fitting(s) (A) and the hose (B) from the rear side of the fuel tank. Slide the clamps back, then twist the hose as you pull to avoid damaging it.
USA and Canada models
2. Push the tabs (A) in, and pull the retainer (B) up, then disconnect the fuel vapor hose (C) from the fuel vent tube (D).
Mexico model
3. Disconnect the fuel vent tube (A) from the front side of the fuel tank. Slide the clamps back, then twist the hose as you pull to avoid damaging it.
4. Place a jack or other support under the fuel tank (A).
5. Remove the straps (B), then remove the fuel tank carefully.
6. Remove the fuel tank protector (A).
Installation
1. Fuel Tank Assembly
NOTE: Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions. Service Precautions
1. Install the fuel tank protector (A).
2. Place a jack or other support under the fuel tank (A).
3. Install the fuel tank with the straps (B).
USA and Canada models
Mexico model
4. Connect the quick-connect fitting (s) (A) and the hose (B) at the rear side of the fuel tank.
NOTE:
* New fuel tank has a ring pull (C) at the fuel hose connectors. When you connect the hose and confirm that the connection is secure, remove the ring pull by pulling it down.
* Before connecting the fuel fill pipe and the quick-connect fitting, check for dirt, and clean them if needed, taking care not to damage the fuel fill pipe or other parts.
USA and Canada models
5. Connect the fuel vapor hose (A) to the fuel vent tube (B).
* New fuel tank has a ring pull (C) at the fuel hose connectors. When you connect the hose and confirm that the connection is secure, remove the ring pull by pulling it down.
* Before connecting the fuel fill pipe and the quick-connect fitting, check for dirt, and clean them if needed, taking care not to damage the fuel fill pipe or other parts.
Mexico model
6. Connect the fuel vent tube (A).
2. Fuel Tank Guard Pipe
1. Install the fuel tank guard.
3. Propeller Shaft Assembly
1. Install the propeller shaft assembly (A), then Install new center support bearing mounting bolts (B).
4. Propeller Shaft Differential Side - Reconnection
1. Set the No. 2 propeller shaft (A) to the rear differential companion flange (B) by aligning the reference mark (C) you made during the removal procedure.
2. Install new No. 2 propeller shaft flange bolts (D) to the specified torque.
5. Propeller Shaft Transmission Side - Reconnection
1. Set the No. 1 propeller shaft (A) to the transfer companion flange (B) by aligning the reference mark (C) you made during the removal procedure. Then install new No. 1 propeller shaft flange bolts (D) to the specified torque.
6. Propeller Shaft Protector No.2
1. Install the No. 2 propeller shaft protector (A).
7. Propeller Shaft Protector No.1
1. Install the No. 1 propeller shaft protector (A).
8. Exhaust Pipe B
1. Install the exhaust pipe B with new gaskets (A).
9. Middle Floor Undercover
Left side
Right side
1. Install the left middle floor undercover (A) or the right middle floor undercover (B), then install the bolts (C) and the clips (D, E). Make sure the clips snap into place securely.
10. Front Floor Undercover
1. Install the front floor undercover (A), then install the bolts (B) and the clips (C, D). Make sure the clips snap into place securely.
11. Rear Wheel
1. Install the rear wheel.
NOTE: Before installing the wheel, clean the mating surfaces between the brake disc/drum and the inside of the wheel.
12. Fuel Tank Unit
1. Insert the fuel tank unit (A) partially into the fuel tank with a new O-ring (B).
2. Align the marks (A) on the fuel tank and fuel tank unit, then insert the fuel tank unit into the fuel tank until.
NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.
3. Tighten a new locknut (A) by hand holding the fuel tank unit vertically.
NOTE: Before tightening, align the mark (B) on the locknut to the start of the thread (C).
4. Using the special tool, tighten the locknut to the specified torque.
NOTE:
* After tightening, make sure the marks are still aligned.
* After installation, check the base gasket, visually or by hand, to make sure it is not pinched.
13. Fuel Line/Quick-Connect Fitting - Connection (Fuel Tank Unit)
NOTE: Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions. Service Precautions
1. Connect the quick-connect fitting (A) to the fuel tank unit (B).
14. Fuel Gauge Sending Unit Access Panel
1. Connect the connector (A).
2. Install the access panel (B) to the floor.
15. Battery Terminal - Reconnection
NOTE: If the battery performance is abnormal, test the battery.
1. Clean the battery terminals.
2. Connect the positive cable (A) to the battery.
NOTE: Always connect the positive side first.
3. Connect the negative cable (B) to the battery.
4. Apply multipurpose grease to the terminals to prevent corrosion.
16. Fuel Fill Cap
1. Install the fuel fill cap.
17. Fuel Line Leak Check
1. Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.