FUEL TANK REMOVAL/INSTALLATION [L8, LF, L5]

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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 [L8, LF, L5].)

3.  Disconnect the quick release connector (engine compartment, fuel distributor side). (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [L8, LF, L5].)

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

5.  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 [L8, LF, L5].)
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.
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.

6.  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 [L8, LF, L5].)
2.  Disconnect the negative battery cable.
Without using M-MDS
1.  Disconnect the negative battery cable to stop the fuel pump.

7.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L8, LF, L5].)

8.  Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

9.  Remove the rear trailing link under cover. (See REAR TRAILING LINK REMOVAL/INSTALLATION.)

10.  Remove in the order indicated in the table.

11.  Install in the reverse order of removal.

12.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [L8, LF, L5].)

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1
Fuel tank
(See Fuel Tank Component Removal Note.)
2
Joint hose
(See Joint Hose Installation Note.)
3
Breather hose
(See Breather Hose Installation Note.)
4
Insulator
(See Rivet Removal Note.)
5
Fuel-filler cap
6
Dust cover
7
Fuel-filler pipe
(See Fuel-Filler Pipe Removal Note.)
8
Nonreturn valve


Fuel Tank Component Removal Note

1.  Remove the rear seat cushion. (4SD) (See REAR SEAT CUSHION REMOVAL/INSTALLATION [4SD].)

2.  Lift up the rear seat cushion. (5HB) (See REAR SEAT REMOVAL/INSTALLATION [5HB/WAGON].)

3.  Disconnect the connectors shown in the figure.

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4.  Remove the service hole cover.

5.  Disconnect the following parts shown in the figure.

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(1)  Fuel pump unit connector
(2)  Evaporative hose
(3)  Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [L8, LF, L5]

6.  Remove the fuel tank component.


Rivet Removal Note

Caution
•  Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.
Note
•  The insulator is installed using rivets.
•  When resin stalling the rivet, install the same rivet or M5 bolt and nut.

1.  Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2.  Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Fuel-Filler Pipe Removal Note

1.  Remove the rear tire (LH). (WGN)

2.  Remove the fuel-filler pipe.


Breather Hose Installation Note

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

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Joint Hose Installation Note

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

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