Fuel Tank: Service and Repair
REMOVAL1. PRECAUTION
2. DISCHARGE FUEL SYSTEM PRESSURE
a. Discharge fuel system pressure.
3. REMOVE COWL TOP VENTILATOR LOUVER RH
4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
5. REMOVE REAR SEAT ASSEMBLY (for Power Seat)
a. Remove the rear seat assembly.
6. REMOVE REAR SEAT ASSEMBLY (for Ottoman)
a. Remove the rear seat assembly.
7. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Type)
a. Remove the rear seat cushion assembly.
8. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the connector from the fuel suction with pump and gauge tube assembly.
9. REMOVE FUEL TANK MAIN AND RETURN TUBE
a. Disconnect the fuel main tube and fuel return tube.
1. Remove the 2 tube joint clips and 2 fuel tubes.
NOTE:
- Remove any dirt and foreign matter on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
10. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the fuel sender gauge connector.
11. REMOVE EXHAUST PIPE ASSEMBLY
a. Remove the exhaust pipe.
12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
a. Remove the propeller with center bearing shaft.
13. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel main tube.
NOTE:
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.
b. Disconnect the fuel return tube.
NOTE:
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel return tube.
- If the pipe and connector are stuck together, pinch the vent tube between your fingers and turn it carefully to free it. Then disconnect the fuel return tube.
c. Loosen the clamp and disconnect the filler pipe hose.
d. Place a mission jack under the fuel tank.
e. Remove the 4 bolts and 2 fuel tank bands.
f. Lower the mission jack so that the fuel tank breather tube can be disconnected.
NOTE: Make sure that no load is applied to the fuel filler pipe.
HINT: Lower the mission jack slowly.
g. Disconnect the fuel tank breather tube subassembly.
NOTE:
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the breather tube.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the breather tube.
h. Disconnect the fuel tank vent hose sub-assembly.
1. Pinch the retainer and then raise it.
NOTE:
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the vent hose contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the vent hose.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.
i. Lower the mission jack to remove the fuel tank from the vehicle.
NOTE:
- Do not allow the fuel tank to contact the vehicle, especially the differential.
- Make sure that the fuel tank is free from the fuel tank vent hose sub-assembly.
HINT: Lower the mission jack slowly.
14. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
a. Remove the 8 bolts and fuel vent tube set plate.
b. Disconnect the fuel hose.
c. Remove the fuel suction with pump and gauge tube from the fuel tank.
NOTE:
- Make sure that the sender gauge arm does not bend.
- Do not damage the fuel suction tube with pump and gauge.
d. Remove the gasket.
15. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Remove the 5 screws and fuel sender gauge.
b. Remove the gasket.
16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Remove the 6 clamps and fuel tank main tube from the fuel tank.
b. Remove the fuel hose clamp.
17. REMOVE FUEL TANK PROTECTOR NO.2
a. Remove the bolt and clip and fuel tank protector from the fuel tank.
b. Remove the clamp from the fuel tank.
18. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY
a. Disconnect the fuel tank vent hose sub-assembly.
NOTE:
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the vent hose.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.
19. REMOVE FUEL TANK CUSHION
a. Remove the 3 tank cushions.
b. Remove the tank protector and 5 tank cushions.
INSTALLATION
1. INSTALL FUEL TANK CUSHION
a. Install the 5 tank cushions and fuel tank protector.
b. Install the 3 tank cushions.
2. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY
a. Install the vent hose to the fuel tank.
1. Align the fuel tank vent hose connector with the pipe, then push in the fuel tank vent hose connector until the retainer makes a "click" sound to install the fuel tank vent hose to the fuel tank.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tank vent hose connector and pipe before this procedure.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tank vent hose connector.
3. INSTALL FUEL TANK PROTECTOR NO.2
a. Install the clamp to the fuel tank.
b. Install the bolt and clip and fuel tank protector to the fuel tank.
4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Install the fuel hose clamp.
b. Install the fuel tank main tube to the fuel tank with the 6 clamps.
5. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Install a new gasket and sender gauge to the fuel tank with the 5 screws.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
6. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
a. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
b. Connect the fuel hose, and set the fuel suction with pump and gauge.
NOTE:
- Be careful not to bend the arm of the fuel sender gauge.
- When connecting the fuel hose, do not forcibly pull the hose.
c. Install the set plate with the 8 bolts.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
HINT: Align the protrusion of the set plate with the cutout of the fuel suction pump and gauge.
7. INSTALL FUEL TANK SUB-ASSEMBLY
a. Set the fuel tank on a mission jack.
b. Raise the mission jack so that the fuel tank breather tube can be connected.
HINT: Raise the mission jack slowly.
c. Connect the fuel tank breather tube sub-assembly.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
d. Connect the fuel vent hose.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
e. Slowly raise the mission jack, and install the 2 fuel tank bands with the 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
NOTE:
- Do not allow the fuel tank to contact the vehicle, especially the differential.
- Make sure that the fuel tank is free from the fuel tank vent hose sub-assembly.
f. Connect the filler pipe hose to the fuel tank.
g. Tighten the clamp.
h. Connect the fuel main tube.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
i. Connect the fuel return tube.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
8. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
a. Install the propeller with center bearing shaft.
9. INSTALL EXHAUST PIPE ASSEMBLY
a. Install the exhaust pipe.
10. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel sender gauge connector.
b. Install the service hole cover with new butyl tape.
11. INSTALL FUEL TANK MAIN AND RETURN TUBE
a. Install the fuel main tube and fuel return tube with the 2 tube joint clips.
NOTE:
- Check that there are no scratches or foreign objects on the connecting parts.
- Check that the fuel tube joint is inserted securely.
- Check that the tube joint clips are on the collars of the fuel tube joints.
- After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
12. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
a. Connect the connector.
b. Install the service hole cover with new butyl tape.
13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
14. REMOVE COWL TOP VENTILATOR LOUVER RH
15. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
16. CHECK FOR FUEL LEAKS
17. INSTALL REAR SEAT ASSEMBLY (for Power Seat)
a. Install rear seat assembly.
18. INSTALL REAR SEAT ASSEMBLY (for Ottoman)
a. Install rear seat assembly.
19. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Type)
a. Install rear seat cushion assembly.