Fuel Tank: Service and Repair

Fuel Tank:

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY
4. REMOVE REAR FLOOR SERVICE HOLE COVER
5. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY
6. REMOVE FUEL TANK VENT TUBE SET PLATE
7. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
8. DRAIN FUEL
9. REMOVE CENTER EXHAUST PIPE ASSEMBLY
10. REMOVE FRONT FLOOR BRACE RH

a. Remove the bolt and 2 nuts, and remove the front floor brace RH.

11. REMOVE FRONT FLOOR BRACE LH

a. Remove the bolt and 2 nuts, and remove the front floor brace LH.

12. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY

a. Remove the set bolt and set nut of the No. 2 parking brake cable assembly.

13. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY

a. Remove the set bolt and set nut of the No. 3 parking brake cable assembly.

14. REMOVE REAR STABILIZER BAR NO. 1 BRACKET

a. Remove the 4 bolts and 2 rear stabilizer bar No. 1 brackets.

15. REMOVE FUEL TANK PROTECTOR LOWER CENTER

a. Remove the 4 bolts and 2 clips.
b. Remove the fuel tank protector.

16. REMOVE FUEL TANK ASSEMBLY

a. Disconnect the fuel pump tube.
1. Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration.
2. Pull out the fuel tank main tube.

NOTE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
- It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Only disconnect the quick connector by hand.
- Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling the connector to release it. Pull the connector off the pipe carefully.

b. Disconnect the No. 1 fuel tube.
1. Pinch the tube connector and then pull out the No. 1 fuel tube.

NOTE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
- It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Only disconnect the quick connector by hand.
- Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling the connector to release it. Pull the connector off the pipe carefully.

c. Place a transmission jack under the fuel tank assembly.

d. Remove the 2 set bolts of the fuel tank bands. (*1)
e. Remove the hose clamp and disconnect the fuel tank to filter pipe hose. (*2)
f. Slightly lower the transmission jack.
g. Disconnect the fuel tank vent hose from the charcoal canister. (*3)
1. Push the connector deep into the charcoal canister to release the locking pin.
2. Pinch portion A.
3. Pull out the connector.

h. Remove the fuel tank.

i. Remove the 2 pins and 2 fuel tank bands as shown in the illustration.

j. Remove the 4 clip nuts.

17. REMOVE FUEL TANK VENT HOSE

a. Push the connector deep into the charcoal canister to release the locking pin.
b. Pinch portion A.
c. Pull out the connector.

18. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY

a. Remove the fuel pump tube from the fuel main tube support.

19. REMOVE FUEL MAIN TUBE SUPPORT

a. Remove the bolt and tube support.

20. REMOVE NO. 2 FUEL TANK CUSHION

a. Remove the 7 No. 2 fuel tank cushions.

INSTALLATION

1. INSTALL NO. 2 FUEL TANK CUSHION

a. Install 7 new No. 2 fuel tank cushions to the fuel tank.

2. INSTALL FUEL MAIN TUBE SUPPORT

a. Install the fuel main tube support with the bolt.

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

3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY

a. Install the fuel pump tube to the fuel main tube support.

4. INSTALL FUEL TANK VENT HOSE

a. Install the fuel tank vent hose.

5. INSTALL FUEL TANK ASSEMBLY

a. Install the 4 clip nuts.

b. Install the 2 fuel tank bands with the 2 pins.
c. Set the fuel tank assembly onto the transmission jack.

d. Raise the transmission jack so that the fuel tank vent hose can be connected. (*1)

NOTE: Slowly raise the jack to prevent the fuel tank assembly from dropping.

e. Connect the fuel tank inlet pipe with the fuel filter pipe clamp. (*2)
f. Tighten the 2 set bolts of the fuel tank bands. (*3)

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

g. Connect the No. 1 fuel tube.
1. Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound.

NOTE:
- Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on any part of the connector.
- After connecting the connector, check if the fuel tube connector and the pipe are securely connected by pulling on them.

h. Connect the fuel pump tube.
1. Push the fuel tube connector into the pipe and push up the retainer so that the claws engage.

NOTE:
- Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on any part of the connector.
- After connecting the connector, check if the fuel tube connector and the pipe are securely connected by pulling on them.

6. INSTALL FUEL TANK PROTECTOR LOWER CENTER

a. Install the fuel tank protector with the 4 bolts and 2 clips.

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

7. INSTALL REAR STABILIZER BAR NO. 1 BRACKET

a. Install the 2 rear stabilizer bar No. 1 brackets with the 4 bolts.

Torque: 31 N.m (316 kgf.cm, 23 ft.lbf)

8. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY

a. Install the No. 3 parking brake cable assembly with the bolt and nut.

Torque:
Bolt 6.0 N.m (61 kgf.cm, 53 in.lbf)
Nut 8.5 N.m (87 kgf.cm, 75 in.lbf)

9. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY

a. Install the No. 2 parking brake cable assembly with the bolt and nut.

Torque:
Bolt 6.0 N.m (61 kgf.cm, 53 in.lbf)
Nut 8.5 N.m (87 kgf.cm, 75 in.lbf)

10. INSTALL FRONT FLOOR BRACE LH

a. Install the front floor brace LH with the bolt and 2 nuts.

Torque: 56 N.m (571 kgf.cm, 41 ft.lbf)

11. INSTALL FRONT FLOOR BRACE RH

a. Install the front floor brace RH with the bolt and 2 nuts.

Torque: 56 N.m (571 kgf.cm, 41 ft.lbf)

12. INSTALL CENTER EXHAUST PIPE ASSEMBLY
13. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
14. INSTALL FUEL TANK VENT TUBE SET PLATE
15. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY
16. ADD FUEL
17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
18. CHECK FOR FUEL LEAKS
19. CHECK FOR EXHAUST GAS LEAKS
20. INSTALL REAR FLOOR SERVICE HOLE COVER
21. INSTALL REAR SEAT CUSHION ASSEMBLY
22. PERFORM INITIALIZATION
a. Perform initialization procedures

HINT: Some systems need initialization after reconnecting the cable to the negative battery terminal.