Fuel Tank: Service and Repair

FUEL TANK


Removal and Installation












REMOVAL

WARNING:
Follow the "General Precautions" before working on the fuel system. Service Precautions.
1. Drain the fuel from the fuel tank, if necessary.
- Position the vehicle so it is level.
2. Remove the fuel filler cap to release the pressure from inside the fuel tank.





3. Check the fuel level on level gauge. If the fuel gauge indicates more than the level as shown (full or almost full), drain the fuel from the fuel tank until the fuel gauge indicates the level as shown, or less.
- If the fuel pump does not operate, use the following procedure to drain the fuel to the specified level after disconnecting the fuel filler hose from the fuel filler pipe.
a. Insert a suitable hose of less than 15 mm (0.59 in) diameter into the fuel filler pipe through the fuel filler opening to drain the fuel from fuel filler pipe.
b. Insert a suitable hose into the fuel tank through the fuel filler hose to drain the fuel from the fuel tank.
- As a guide, the fuel level reaches the fuel gauge position as shown, or less, when approximately 14 liters (3 3/4 US gal, 3 1/8 Imp gal) of fuel are drained from the fuel tank.
4. Remove the LH rear wheel and tire. Rotation.





5. Disconnect the fuel filler hose from the fuel filler pipe and disconnect the vent hose quick connector.
6. Release the fuel pressure from the fuel lines. Testing and Inspection.
7. Disconnect the battery negative terminal. Removal and Replacement.
8. Remove the second row LH rear seat and the third row rear seat. Second Row Outboard, LH Side Seat (w/o power folding), LH Side Seat (power folding).
9. Remove the second and third row rear seat belt buckles mounted on the floor. Second Row Seat Belt, Third Row Seat Belt.
10. Remove the LH center pillar trim, the LH rear trim panel, and the LH rear side door kick plate and weather stripping. Service and Repair.
11. Remove the second row rear center console and base. Second Row Center.
12. Reposition the floor carpet out of the way to access the inspection hole cover, located under the center LH rear seat.





13. Remove the inspection hole cover by turning the retainers 90�
degrees clockwise.
- Remove the O-ring.





14. Disconnect the fuel level sensor, fuel filter, and fuel pump assembly electrical connector, the EVAP hose, and the fuel feed hose.





Disconnect the quick connector as follows:
- Hold the sides of the connector, push in tabs and pull out the tube.
- If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling.

CAUTION:





- The quick connector can be disconnected when the tabs are completely depressed. Do not twist the quick connector more than necessary.
- Do not use any tools to disconnect the quick connector.
- Keep the resin tube away from heat. Be especially careful when welding near the tube.
- Prevent any acid liquids such as battery electrolyte, from getting on the resin tube.
- Do not bend or twist the resin tube during connection.
- Do not remove the remaining retainer on the hard tube (or the equivalent) except when the resin tube or the retainer is replaced.
- When the resin tube or hard tube, or the equivalent, is replaced, also replace the retainer with a new one (white colored retainer).





- To keep the quick connector clean and to avoid damage and contamination from foreign materials, cover the quick connector with plastic bags or suitable material as shown.
15. Remove the four bolts and remove the fuel tank shield, if equipped.
16. Remove the propeller shaft. Removal And Installation (2F1310), Removal And Installation (2S1410).
17. Disconnect fuel filler hose, and vent hose at the fuel tank side.





18. Remove the fuel tank strap bolts while supporting the fuel tank with a suitable lift jack.
19. Disconnect the EVAP hose from the molded clip in the top of the fuel tank while lowering the fuel tank.
20. Lower the fuel tank using a suitable lift jack and remove it.





21. If necessary, remove the lock ring using Tool.

Tool number : - (J-46536)

22. If necessary, remove the fuel level sensor, fuel filter, and fuel pump assembly. Discard the fuel level sensor, fuel filter, and fuel pump assembly O-ring.

CAUTION:
- Do not bend the float arm during removal.
- Avoid impacts such as dropping when handling the components.

INSTALLATION
Installation is in the reverse order of removal.
- For installation, use a new fuel level sensor, fuel filter, and fuel pump assembly O-ring.
- Connect the quick connector as follows:
- Check the connection for any damage or foreign materials.
- Align the connector with the pipe, then insert the connector straight into the pipe until a click is heard.





- After connecting the quick connector, make sure that the connection is secure by checking as follows:
- Pull the tube and the connector to make sure they are securely connected.
- Visually inspect the connector to make sure the two retainer tabs are securely connected.

INSPECTION AFTER INSTALLATION
1. Turn the ignition switch ON but do not start engine, then check the fuel pipe and hose connections for leaks while applying fuel pressure.
2. Start the engine and rev it above idle, then check that there are no fuel leaks at any of the fuel pipe and hose connections.