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FUEL TANK REMOVAL/INSTALLATION

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  Warning

  • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
  • 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 a vehicle.
  • 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.

1. Level the vehicle.

2. Complete the "BEFORE REPAIR PROCEDURE". (See BEFORE REPAIR PROCEDURE.)

3. Disconnect the negative battery cable.

4. Drain the fuel using the following procedure.

  (1) Disconnect the breather hose (when the fuel tank is full) or the joint hose (except when the fuel tank is full) from the fuel-filler pipe.
  (2) Drain the fuel by tilting the breather hose (when the fuel tank is full) or the joint hose (except when the fuel tank is full).
  (3) Siphon the fuel from the fuel tank using a fuel drawing pump.

5. Remove the catalytic converter. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITHOUT WU-TWC], EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH WU-TWC].)

6. Remove the crossmember and the member. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITHOUT WU-TWC], EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH WU-TWC].)

7. Remove the catalytic converter rubber hangers and lower the catalytic converter to where the insulator can be removed.

8. Remove in the order indicated in the table.

9. Install in the reverse order of removal.

10. Complete the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE.)

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1 | Insulator
2 | Fuel hose protector
3 | Fuel hose (Return) (See FUEL HOSE (FUEL TANK SIDE) REMOVAL/INSTALLATION)
4 | Evaporative hose (See Evaporative Hose Removal Note) (See Evaporative Hose Installation Note)
5 | Fuel hose (Main) (See FUEL HOSE (FUEL TANK SIDE) REMOVAL/INSTALLATION)
6 | Joint hose (See Joint Hose Installation Note)
7 | Breather hose (See Breather Hose Installation Note)
8 | Strap
9 | Fuel tank assembly (See Fuel Tank Assembly Removal Note)
10 | Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION)
11 | Charcoal canister (See CHARCOAL CANISTER REMOVAL/INSTALLATION)
12 | Fuel-filler cap
13 | Fuel-filler pipe

## Evaporative Hose Removal Note

  Caution

  • To avoid damaging the evaporative hose, always disconnect from the evaporative pipe side.

1. Disengage the disconnected evaporative hose from the fuel filter (high-pressure) bracket and set it out of the way as shown in the figure.

## Breather Hose Installation Note

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

## Fuel Tank Assembly Removal Note

  Caution

  • To avoid damaging the fuel hose, charcoal canister and other parts, do not forcefully raise the fuel tank component and carefully move the hoses out the way when removing.

1. Carefully lower (30-60mm) the fuel tank component and disconnect the fuel pump unit connector.

## 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 clamps as shown in the figure.

## Evaporative Hose Installation Note

1. Push the evaporative hose onto the evaporative pipe unit it reaches the stopper.

2. Assemble the clamp with the tabs pointing sideward.

3. Install the clamp by aligning it with the clamp marks remaining on the hose.