Fuel Tank: Service and Repair

FUEL TANK

REMOVAL AND INSTALLATION [AWD]

FUEL TANK

Pre-Removal Operation And Post-Installation Operation:

Removal Steps 1-24 (Part 1):

Removal Steps 1-24 (Part 2):

FUEL TANK FILLER TUBE

Removal Steps 5-29:

REMOVAL SERVICE POINTS

]A[ FUEL PUMP MODULE CONNECTOR/FUEL TANK DIFFERENTIAL PRESSURE SENSOR CONNECTOR/FUEL MAIN PIPE DISCONNECTION




1. Remove the floor inspection lid (LH).




2. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.
3. Release the fuel pressure in the fuel line. [Refer to MFI, On-vehicle Service- Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines).]




4. Insert a flat-tip screwdriver [6mm (0.24 inch) wide and 1mm (0.04 inch) thick] into the retainer of the fuel main pipe.




5. Turn the flat-tip screwdriver about 90 degrees to push up the retainer, and disconnect the fuel main pipe from the fuel pump module.

]B[ FUEL LEVEL SENSOR (SUB) CONNECTOR DISCONNECTION




1. Remove the floor inspection lid (RH).




2. Disconnect the fuel level sensor (sub) connector.

]C[ REAR DIFFERENTIAL SUPPORT MEMBER MOUNTING BOLT/FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL







1. Remove the mounting bolts of rear differential support member and tilt the differential carrier assembly. (Refer to Rear Axle, Differential Carrier Assembly).
2. Hold the fuel tank assembly with the transaxle jack, and remove the connecting bolts of fuel tank band and the connecting nuts of fuel tank assembly.
3. Remove the fuel tank assembly in the tilt direction, paying attention not to bump it against the rear differential carrier.

]D[ FUEL LEVEL SENSOR (SUB)/SUCTION HOSE/FUEL PUMP MODULE REMOVAL

CAUTION: Pay attention not to damage the fuel level sensor, the float of the fuel level sensor (sub) and float of the fuel pump module when removing the fuel level sensor (sub) and fuel pump module from the fuel tank.






While removing the fuel pump module from the fuel tank, disconnect the suction hose from the fuel pump module to remove the fuel pump module from the fuel tank.

INSTALLATION SERVICE POINTS

[A] FUEL PUMP MODULE/SUCTION HOSE INSTALLATION

CAUTION:
- Pay attention not to damage the fuel level sensor and the float of the fuel pump module when installing it to the fuel tank. Pay attention to prevent the float of fuel level sensor from being trapped by the suction hose inside the fuel tank.
- When installing the fuel pump module to the fuel tank, check that the fuel level sensor moving area moves smoothly.






While inserting the fuel pump module into the fuel tank, connect the suction hose to the fuel pump module to install the fuel pump module to the fuel tank.

[B] FUEL LEVEL SENSOR (SUB) INSTALLATION

CAUTION: Pay attention not to damage the fuel level sensor (sub) and the float of the fuel level sensor (sub) when installing it to the fuel tank.

[C] FUEL MAIN PIPE CONNECTION




1. Before the installation, push up the retainer of the fuel main pipe.




2. Connect the connector of fuel main pipe to the fuel pump module securely and push down the retainer of the connector to lock it firmly.
3. After the installation, slightly pull the fuel main pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.