Fuel Tank: Service and Repair
Removal & Installation and Disassembly & Reassembly1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE REAR FLOOR BOARD NO.2
3. REMOVE DECK FLOOR BOX REAR
4. REMOVE REAR FLOOR BOARD NO.3
5. DISCONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
6. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER
7. REMOVE FLOOR PANEL BRACE FRONT
8. REMOVE EXHAUST PIPE ASSY FRONT
a. Using a clip remover, remove the clip.
b. Pull off the floor carpet front.
c. Disconnect the heated oxygen sensor connector.
d. Remove the grommet from the vehicle.
e. Remove the bolts and 4 compression springs.
f. Remove the exhaust pipe front from the 2 exhaust pipe supports.
g. Remove the 2 gaskets from the exhaust manifold and exhaust pipe front.
9. REMOVE REAR SEAT CUSHION ASSY
10. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the butyl tape, then remove the rear floor service hole cover.
b. Disconnect the fuel pump connector.
c. Disconnect the wire to wire connector.
11. REMOVE FUEL TANK ASSY
a. Disconnect the fuel tank to canister tube.
1. Pinch the retainer of the fuel tube connector, then pull out the fuel tube connector to disconnect the fuel tank to canister tube from the pipe.
NOTE:
- Remove dirt or foreign objects on the fuel tube connector before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tank to canister tube.
- If the fuel tube connector and pipe are stuck, push and pull them to release.
b. Disconnect the fuel tank main tube no. 2.
1. Remove the checker of the fuel tube connector from the pipe.
2. Pinch the retainer of the fuel tube connector, then pull out the fuel tube connector to disconnect the fuel tank main tube No. 2 from the pipe.
NOTE:
- Remove dirt or foreign objects on the fuel tube connector before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tank main tube No. 2.
- If the fuel tube connector and pipe are stuck, push and pull them to release.
c. Disconnect the fuel tank vent hose.
1. Pinch the retainer and pull out the fuel tank vent connector No. 2 with the fuel tank vent connector No. 2 pushed to the pipe side to disconnect the fuel tank vent hose from the charcoal canister filter.
NOTE:
- Remove dirt or foreign objects on the fuel tank vent connector No. 2 before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tank vent connector No. 2 has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tank vent hose.
- If the fuel tank vent connector No. 2 and pipe are stuck, push and pull them to release.
d. Disconnect the fuel suction tube.
1. Pinch the retainer and pull out the quick connector with the quick connector pushed to the pipe side to disconnect the fuel suction tube from the fuel tank to filler pipe.
NOTE:
- Remove dirt or foreign objects on the quick connector before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tank vent connector No. 2 has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the fuel suction tube.
- If the quick connector and pipe are stuck, push and pull them to release.
e. Disconnect the charcoal canister tube No. 1.
1. Pinch the retainer and pull out the quick connector with the quick connector pushed to the pipe side to disconnect the charcoal canister tube No. 1 from the fuel tank to filler pipe.
NOTE:
- Remove dirt or foreign objects on the quick connector before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tank vent connector No. 2 has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the charcoal canister tube No. 1.
- If the quick connector and pipe are stuck, push and pull them to release.
f. Set a transmission jack to the fuel tank.
g. Remove fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe.
h. Remove the 4 bolts, then remove the fuel tank bands No. 1 RH and LH.
i. Operate the transmission jack, then disconnect the fuel tank inlet pipe.
j. Operate the transmission jack, then remove the fuel tank.
12. REMOVE FUEL TANK MAIN TUBE SUB-ASSY NO.2
a. Remove the 3 nuts, then remove the fuel tank bracket RR.
b. Remove the wire to wire connector from the fuel tank bracket RR.
c. Remove the tube of the fuel tank main tube No. 2 from the clamp.
d. Remove the checker of the fuel tube connector from the pipe.
e. Pinch the retainer of the fuel tube connector, then pull out the fuel tube connector to disconnect the fuel tank main tube No. 2 from the pipe.
NOTE:
- Remove dirt or foreign objects on the fuel tube connector before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tank main tube No. 2.
- If the fuel tube connector and pipe are stuck, push and pull them to release.
13. REMOVE FUEL SUCTION TUBE SUB-ASSY
a. Remove the tube of the fuel tank suction tube from the 2 fuel tube with grommet clamps No. 1.
b. Pinch the retainer and pull out the quick connector with the quick connector pushed to the pipe side to disconnect the fuel suction tube from the pipe.
NOTE:
- Remove dirt or foreign objects on the quick connector before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tank vent connector No. 2 has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the fuel suction tube.
- If the quick connector and pipe are stuck, push and pull them to release.
14. REMOVE FUEL TANK TO CANISTER TUBE
a. Remove the tube of the fuel tank to canister tube from the clamp.
b. Remove the tube of the fuel tank to canister tube from the 2 fuel tube with grommet camps No. 1.
c. Remove the fuel tank to canister tube from the charcoal canister.
15. REMOVE TRAP W/OUTLET VALVE CANISTER ASSY
a. Disconnect the VSV connector.
b. Remove the clamp from the fuel tank vent hose and charcoal canister hose.
c. Remove the tube of the fuel tank vent hose from the 2 fuel tube with grommet clamps No.1.
d. Remove the 2 bolts, then remove the trap with outlet valve canister and ground terminal of the fuel tank wire.
e. Remove the gasket from the fuel tank.
f. Remove the 2 clamps from the trap with outlet valve canister.
16. REMOVE FUEL TANK VENT HOSE
a. Pinch the retainer and pull out the fuel tank vent connector No. 2 with the fuel tank vent connector No. 2 pushed to the pipe side to disconnect the fuel tank vent hose from the trap with outlet valve canister.
NOTE:
- Remove dirt or foreign objects on the fuel tank vent connector No. 2 before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tank vent connector No. 2 has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tank vent hose.
- If the fuel tank vent connector No. 2 and pipe are stuck, push and pull them to release.
17. REMOVE FUEL TANK WIRE
a. Remove the clamp.
b. Disconnect the VSV connector.
c. Disconnect the vapor pressure sensor connector.
d. Remove the 3 wire harness clamps.
18. REMOVE CHARCOAL CANISTER ASSY
a. Disconnect the charcoal canister hose from the fuel tank retainer.
b. Disconnect the charcoal canister outlet hose No. 1 from the fuel tank.
c. Remove the bolt and 2 nuts, then remove the charcoal canister.
d. Remove the spring nut from the fuel tank.
19. REMOVE VAPOR PRESSURE SENSOR ASSY
a. Remove the tube joint clip, then pull out the vapor pressure sensor from the fuel tank retainer.
NOTE:
- Remove dirt or foreign objects on vapor pressure sensor before this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting as the vapor pressure sensor has the O-ring that seals the plug.
- Perform this work by hand. Do not use any tools.
20. REMOVE FUEL TANK RETAINER LH
a. Insert a clip remover between the fuel tank retainer and gasket, then remove the fuel tank retainer by lifting it little by little.
NOTE:
- The fuel tank retainer is made of resin and easily damaged if removed or installed forcibly. Handle the part correctly to ensure the sealing.
- After removing, check that the contact surface of the fuel tank retainer on the fuel tank is not damaged.
b. Remove the gasket from the fuel tank.
21. REMOVE FUEL TUBE W/GROMMET CLAMP NO.1
a. Remove the 2 fuel tube with grommet clamps No. 1.from the fuel tank.
22. REMOVE FUEL TANK CUSHION NO.1
a. Remove the 9 fuel tank cushions No. 1 from the fuel tank.
23. INSTALL FUEL TANK CUSHION NO.1
a. Install new 9 fuel tank cushions to the fuel tank.
24. INSTALL FUEL TUBE W/GROMMET CLAMP NO.1
25. INSTALL FUEL TANK RETAINER LH
a. Install a new gasket to the fuel tank.
b. While being careful that the gasket does not drop in the fuel tank, insert the fuel tank retainer to the fuel tank so the protrusion of the fuel tank retainer is in the middle of the 2 convexes of the fuel tank.
26. INSTALL VAPOR PRESSURE SENSOR ASSY
a. Push the vapor pressure sensor to the plug of the fuel tank retainer, then install the tube joint clip.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the vapor pressure sensor and fuel tank retainer before this work.
- Check that the vapor pressure sensor is securely inserted to the end.
- Check that the tube joint clip is on the collar of the vapor pressure sensor.
- After installing the tube joint clip, check that the vapor pressure sensor cannot be pulled out.
27. INSTALL CHARCOAL CANISTER ASSY
Torque: 6.0 Nm (61 kgf.cm, 53 in.lbf)
28. INSTALL FUEL TANK WIRE
29. INSTALL FUEL TANK VENT HOSE
a. Align the fuel tank vent connector No. 2 with the pipe, then push in the fuel tank vent connector No. 2 until the retainer makes a "click" sound to install the fuel tank vent hose to the trap with outlet valve canister.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tank vent connector No. 2 and pipe before this work.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tank vent connector No. 2.
30. INSTALL TRAP W/OUTLET VALVE CANISTER ASSY
a. Install a new gasket to the fuel tank.
b. While being careful that the gasket does not drop in the fuel tank, insert the trap with outlet valve canister to the fuel tank.
c. Install the trap with outlet valve canister and ground terminal of the fuel tank wire with the 2 bolts.
Torque: 6.0 Nm (61 kgf.cm, 53 in.lbf)
d. Install the tube of the fuel tank vent hose to the 2 fuel tube with grommet clamps. No. 1.
e. Install the clamp to the fuel tank vent hose and charcoal canister hose.
f. Connect the VSV connector.
31. INSTALL FUEL TANK TO CANISTER TUBE
32. INSTALL FUEL SUCTION TUBE SUB-ASSY
a. Align the quick connector with the pipe, then push in the quick connector until the retainer makes a "click" sound to install the fuel suction tube to the pipe.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the quick connector and pipe before this work.
- After connecting the fuel suction tube, check that the fuel suction tube is securely connected by pulling the quick connector.
b. Install the tube of the fuel suction tube to the 2 fuel tube with grommet clamps No. 1.
33. INSTALL FUEL TANK MAIN TUBE SUB-ASSY NO.2
a. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound to install the fuel tank main tube No. 2 to the pipe.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector.
- After connecting the fuel tank main tube No. 2, check that the fuel tank main tube No. 2 is securely connected by pulling the fuel tube connector.
b. Install the checker to the pipe.
c. Install the tube of the fuel tank main tube No. 2 to the clamp.
d. Install the connector clamp to the fuel tank bracket RR.
e. Install the fuel tank bracket RR with the 3 nuts.
Torque: 6.0 Nm (61 kgf.cm, 53 in.lbf)
34. INSTALL FUEL TANK ASSY
a. Set the fuel tank to a transmission jack.
b. Operate the transmission jack, then install the fuel tank to the vehicle.
c. Operate the transmission jack, then connect the fuel tank inlet pipe.
d. Install the fuel tank bands No. 1 RH and LH with the 4 bolts.
Torque: 39 Nm (400 kgf.cm, 29 ft.lbf)
e. Install the fuel tube connector and fuel filler pipe clamp to the fuel tank inlet pipe.
f. Connect the charcoal canister tube No. 1.
1. Align the quick connector with the pipe, then push in the quick connector until the retainer makes a "click" sound to connect the charcoal canister tube No. 1 to the fuel tank to filler pipe.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the quick connector and pipe before this work.
- After connecting the charcoal canister tube No. 1, check that the charcoal canister tube No. 1 is securely connected by pulling the quick connector.
g. Connect the fuel suction tube.
1. Align the quick connector with the pipe, then push in the quick connector until the retainer makes a "click" sound to connect the fuel suction tube to the fuel tank to filler pipe.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the quick connector and pipe before this work.
- After connecting the fuel suction tube, check that the fuel suction tube is securely connected by pulling the quick connector.
h. Connect the fuel tank vent hose.
1. Align the fuel tank vent connector No. 2 with the pipe, then push in the fuel tank vent connector No. 2 until the retainer makes a "click" sound to connect the fuel tank vent hose to the charcoal canister filter.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tank vent connector No. 2 and pipe before this work.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the quick connector.
i. Connect the fuel tank main tube No. 2.
1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound to connect the fuel tank main tube No. 2 to the pipe.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before this work.
- After connecting the fuel tank main tube No. 2, check that the fuel tank main tube No. 2 is securely connected by pulling the quick connector.
j. Install the checker to the pipe.
k. Connect the fuel tank to canister tube.
1. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound to connect the fuel tank to canister tube to the pipe.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before this work.
- After connecting the fuel tank to canister tube, check that the fuel tank to canister tube is securely connected by pulling the quick connector.
35. INSTALL EXHAUST PIPE ASSY FRONT
a. Inspect the free length.
1. Using vernier calipers, measure the free length of the compression spring.
Minimum:
40.5mm (1.594 in.) for Exhaust pipe front x Exhaust manifold
38.5mm (1.516 in.) for Exhaust pipe front x Exhaust pipe tail
If the free length is less than minimum, replace the compression spring.
b. Using a wooden block and plastic-faced hammer, tap in a new gasket until it is flush with the exhaust manifold.
NOTE:
- Be careful of the installation direction of a new gasket.
- Do not reuse the removed gasket.
- Never push a new gasket into the exhaust manifold by installing the exhaust pipe front to the exhaust manifold.
c. Install a new gasket to the exhaust pipe front.
NOTE: Be careful of the installation direction of a new gasket.
d. Install the exhaust pipe front to the 2 exhaust pipe supports.
e. Tighten the 4 compression springs and 4 bolts.
Torque: 43 Nm (440 kgf.cm, 32 ft.lbf)
f. Install the grommet of the heated oxygen sensor to the vehicle.
g. Connect the heated oxygen sensor connector.
h. Install the floor carpet front with the clip.
36. CONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
37. CHECK FOR FUEL LEAKS
38. CHECK FOR EXHAUST GAS LEAKS
39. INSTALL FLOOR PANEL BRACE FRONT
40. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER
41. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Attach new butyl tape to the rear floor service hole cover.
b. Connect the wire to wire connector.
c. Connect the fuel pump connector.
d. Install the rear floor service hole cover while adjusting it to the 3 convexes of the floor panel.
NOTE: Be careful that the rear floor service hole cover does not mount on the convex of the floor panel when installing.
42. INSTALL REAR SEAT CUSHION ASSY
43. INSTALL REAR FLOOR BOARD NO.3
44. INSTALL DECK FLOOR BOX REAR
45. INSTALL REAR FLOOR BOARD NO.2
46. POWER WINDOW CONTROL SYSTEM INITIALIZE