Fuel Filler Hose: Service and Repair

Fuel Filler Pipe

REMOVAL

WARNING: Place "NO OPEN FLAMES" signs near the working area.

CAUTION: Be careful not to spill fuel.
1. Release the fuel pressure.
2. Drain fuel.
3. Disconnect the ground cable from battery.






4. Open the fuel filler lid and remove the fuel filler cap.
5. Turn the fuel filler pipe protector in the direction of the arrow to unlock and remove it.






6. Remove the rear wheels.
7. Lift up the vehicle.
8. Remove the rear ABS wheel speed sensor from the rear housing.






9. Remove the rear ABS wheel speed sensor harness from the upper arm.






10. Remove the rear brake hose bracket from rear housing.






11. Remove the rear disc brake assembly and tie it to the body side of the vehicle.






12. Remove the rear exhaust pipe and muffler.
13. Remove the propeller shaft.
14. Remove the fuel tank protector.






15. Remove the parking brake cable from the parking brake assembly.
16. Remove the bolts securing the parking brake cable.






17. Remove the clamp, and pull out the parking brake cable from the back plate.






18. Disconnect the connector (A) from the rear vehicle height sensor, and remove the rear vehicle height sensor. (model with auto headlight beam leveler, left side only)






19. Remove the rear sub frame assembly.

WARNING: A helper is required to perform this work.

1. Support the rear sub frame assembly with a transmission jack.
2. Remove bolts and nuts on the lower side of the rear strut assembly from the rear lateral link.






3. Remove the bolts which secure the rear sub frame assembly to the body.






4. Remove the rear sub frame assembly.
20. Remove the rear mud guard RH.
21. Remove the bolts and nuts which secure fuel filler pipe assembly onto the vehicle body.






22. Disconnect the fuel filler hose (A) and evaporation hose (B) from the fuel filler pipe assembly.






23. Remove the fuel filler pipe assembly from the underside of the vehicle.

INSTALLATION
1. Open the fuel filler lid.
2. Insert the fuel filler pipe assembly into the rubber saucer from inside of the rear fender.
3. Install the fuel filler pipe assembly to vehicle body.

Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)






4. Install the rear mud guard RH.
5. Securely insert the fuel filler hose (A) and evaporation hose (B) until the hose end contacts the spool, then attach the clamp or clip as shown in the figure.

Tightening torque: 2.5 N.m (0.3 kgf-m, 1.8 ft-lb)










6. Install the rear sub frame assembly.

WARNING: A helper is required to perform this work.

1. Support the rear sub frame assembly with a transmission jack.
2. Support the rear sub frame assembly, and install the rear sub frame assembly to the body.

Tightening torque:
T1: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
T2: 145 N.m (14.8 kgf-m, 106.9 ft-lb)






3. Install the lower side of the rear strut to the rear lateral link.

NOTE: Use a new self-locking nut.

Tightening torque: 120 N�m (12.2 kgf-m, 88.5 ft-lb)






7. Install the rear vehicle height sensor and connect the connector (A) to the rear vehicle height sensor. (model with auto headlight beam leveler, left side only)

Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)






8. Insert the parking brake cable into the back plate, and install it with the clamp.






9. Secure the parking brake cable with bolts.

Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)






10. Connect the parking brake cable to the parking brake assembly.
11. Install the fuel tank protector.

NOTE: Use a new self-locking nut.

Tightening torque:
T1: 9 N.m (0.9 kgf-m, 6.6 ft-lb)
T2: 18 N.m (1.8 kgf-m, 13.3 ft-lb)






12. Install the propeller shaft.
13. Install the rear exhaust pipe and muffler.
14. Install the rear disc brake assembly.

Tightening torque: 66 N.m (6.7 kgf-m, 48.7 ft-lb)






15. Install the rear brake hose bracket to the rear housing.

Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)






16. Install the rear ABS wheel speed sensor harness to the upper arm.

NOTE: Prevent the harness identification (line) from being twisted when installing. (RH: Orange line, LH: Green line)






17. Attach the rear ABS wheel speed sensor to the rear housing.

NOTE: Prevent the harness identification (line) from being twisted when installing. (RH: Orange line, LH: Green line)

Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)






18. Lower the vehicle.
19. Install the rear wheels.

Tightening torque: 120 N.m (12.2 kgf-m, 88.5 ft-lb)

20. Connect the battery ground terminal.






21. Inspect the wheel alignment and adjust if necessary.
22. Perform reinitialization of the auto headlight beam leveler system. (model with auto headlight beam leveler)