FUEL TANK REMOVAL/INSTALLATION [ZJ, ZY]

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Warning
•  Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
•  A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.
Caution
•  Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [ZJ, ZY].)

3.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

4.  Remove the service hole cover.

5.  Disconnect the quick release connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [ZJ, ZY].)

6.  Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.

7.  Drain the fuel from the fuel tank using the following procedure:

Using M-MDS
1.  Connect the M-MDS to the DLC-2.
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2.  Using the simulation function “FP”, start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [ZJ, ZY].)
Without using M-MDS
1.  Disconnect the negative battery cable.
2.  Remove the fuel pump relay.
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Caution
•  Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.
3.  Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.
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4.  Connect the negative battery cable and operate the fuel pump. (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY].)
Caution
•  The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

8.  Stop the fuel pump using the following procedure.

Using M-MDS
1.  Using the simulation function “FP”, stop the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [ZJ, ZY].)
2.  Disconnect the negative battery cable.
Without using M-MDS
1.  Disconnect the negative battery cable to stop the fuel pump.

9.  Disconnect the fuel pump unit connector.

10.  Remove the tunnel member. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [ZJ, ZY].)

11.  Remove the middle pipe or presilencer. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [ZJ, ZY].)

12.  Remove in the order indicated in the table.

13.  Install in the reverse order of removal.

14.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [ZJ, ZY].)

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1
Insulator
2
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [ZJ, ZY].)
3
Fuel tank component
(See Fuel Tank Component Removal Note.)
4
Joint hose
(See Joint Hose Installation Note.)
5
Breather hose
(See Breather Hose Installation Note.)
6
Charcoal canister
(See CHARCOAL CANISTER REMOVAL/INSTALLATION [ZJ, ZY].)
7
Fuel pump unit
(See FUEL PUMP UNIT REMOVAL/INSTALLATION [ZJ, ZY].)
8
Fuel-filler cap
9
Fuel-filler cap cover
10
O-ring
11
Dust cover
12
Fuel-filler pipe
(See Fuel-filler Pipe Removal Note.)


Fuel Tank Component Removal Note

1.  Disconnect the joint hose (fuel-filler pipe side).

2.  Disconnect the breather hose (fuel-filler pipe side).

3.  Set the parking cable out of the way.

4.  Remove the fuel tank component.


Fuel-filler Pipe Removal Note

1.  Remove the splash shield (LH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)


Joint Hose Installation Note

1.  Verify that there is no damage to the nonreturn valve built into the fuel-filler pipe.

2.  Install the joint hose and clamp as shown in the figure.

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Breather Hose Installation Note

1.  Install the breather hose and clamp as shown in the figure.

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