Fuel Tank: Service and Repair

Removal procedure # 1

CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis , refer to Driveability and Emissions section.

1. Drain the fuel from the fuel tank. Refer to Fuel Pump Flow Test.
2. Disconnect battery ground cable.
3. Loosen fuel filler cap for reduce the pressure in fuel tank.
4. Support underneath of the fuel tank assembly (1) with a lifter.
5. Disconnect fuel feed hose (7) and fuel return hose (8) near the fuel filter.

NOTE: Plug both ends of the fuel hoses to prevent fuel leakage.

6. Disconnect fuel filler hose (5) and fuel vent hose (6) at the fuel filler neck.

NOTE: Cover fuel hoses to prevent any dust entering.

7. Remove two bolts (4) and remove separator.
8. Remove the five fuel tank assembly fixing bolts (2) and one nut (3).
9. Let down the tank and disconnect the wiring connectors (9, 10).

Removal Procedure # 2




Refer to Fuel Tank in Engine Fuel section.

Installation procedure # 1
1. Raise the fuel tank assembly (1) and install the connectors (9, 10).
2. Install fuel tank assembly along with protectors and tighten the five fixing bolts (2) and one nut (3) to the specified torque.
Torque: 68 N-m (50 lb ft)
3. Install the separator and tighten two bolts (4).
Torque: 10 N-m (95 lb in)
4. Connect fuel filler hose (5) and fuel vent hose and clip them firmly.
5. Connect fuel feed hose and fuel return hose, and clip them firmly.
6. Tighten fuel filler cap with not less than 3 clicks.
7. Connect battery ground cable.