Fuel Tank: Service and Repair
Removal & Installation and Disassembly & Reassembly1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE CHARCOAL CANISTER PROTECTOR
3. REMOVE FUEL TANK FILLER HOSE COVER
a. Remove the 3 bolts and the fuel tank filler hose cover.
4. REMOVE FUEL TANK ASSY
a. Disconnect the fuel tank vent hose
1. Deeply push the connector to release the locking tab.
2. Pinch portion A.
3. Pull out the connector.
b. Disconnect the fuel tank main tube.
1. Pinch the tube connector and then pull out the fuel tank main tube.
NOTE:
- Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
- Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and the connector are stuck, push and pull the connector to release and pull the connector out carefully.
c. Disconnect the fuel tank to filler pipe hose.
1. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
d. Disconnect the fuel tube.
1. Pinch the tube connector and then pull out the fuel tank main tube.
NOTE:
- Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
- Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and the connector are stuck, push and pull the connector to release and pull the connector out carefully.
e. Remove the 2 wire harness clamps
f. Set up a transmission jack under the fuel tank.
g. Remove the 6 set bolts of the 3 fuel tank bands.
h. While operating the transmission jack, unfasten the 4 claws for the wire harness and disconnect the fuel pump connector and vapor pressure sensor connector, then remove the fuel tank and the 3 fuel tank bands from the vehicle
5. REMOVE FUEL TANK MAIN TUBE SUB ASSY
6. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
7. DRAIN FUEL
8. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Loosen the hose clamp bolt and remove the fuel tank to filler pipe hose from the fuel tank.
9. REMOVE FUEL TANK VENT HOSE
a. Remove the hose of the fuel tank vent hose from the 3 hose clamps.
b. Remove the fuel tank vent hose.
1. Deeply push the connector to release the locking tab.
2. Pinch portion A.
3. Pull out the connector.
10. CONNECT FUEL TANK VENT HOSE
11. INSTALL FUEL TANK TO FILLER PIPE HOSE
a. Install a new fuel tank to filler pipe hose as shown in the illustration.
12. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
13. INSTALL FUEL TANK MAIN TUBE SUB ASSY
14. INSTALL FUEL TANK ASSY
a. Set up the fuel tank to the transmission jack.
b. While operating the transmission jack, fasten the 4 claws for the wire harness and connect the fuel pump connector and vapor pressure sensor connector, then install the fuel tank and the 3 fuel tank bands to the vehicle.
c. Tighten the 6 set bolts of the 3 fuel tank bands.
Torque: 33 N.m (336 kgf.cm, 24 ft.lbf)
d. Install the 2 wire harness clamps.
e. Connect the fuel tube.
1. Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound
NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the connector and the pipe are securely connected by pulling on them.
f. Connect the fuel tank to filler pipe hose as shown in the illustration.
g. Connect the fuel tank main tube.
1. Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound.
NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the connector and the pipe are securely connected by pulling on them.
h. Connect the fuel tank vent hose.
15. ADD FUEL
16. CHECK FOR FUEL LEAKS
17. INSTALL FUEL TANK FILLER HOSE COVER
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
18. INSTALL CHARCOAL CANISTER PROTECTOR