Repair Procedure 2 - Fuel Filler Pipe
Replace Fuel Filler Pipe.
PRECAUTIONS:
^ Verify that the fuel level is 3/4 tank or below (to prevent fuel spillage).
^ Verify that there will be NO flames or sparks in the area in which the procedure will take place.
^ Do NOT smoke during this operation.
1. Disconnect engine wire No. 3 (battery negative (-) terminal).
2. Remove the left rear tire.
3. Remove the fuel tank cap assembly.
4. Remove the floor under cover No. 1. Remove the 2 clips and 2 bolts, and then remove the floor under cover No. 1.
5. Remove the fuel tank filler pipe protector.
Remove the nut, and then remove the fuel tank filler pipe protector.
FUEL PIPE CONNECTOR CAUTIONS:
^ Remove any dirt or foreign objects from the connectors before proceeding.
^ Be careful NOT to scratch the 0-ring on the connector or the connector may NOT seal properly upon reconnection.
^ Disconnect the fuel pipe connector by hand. Do NOT use any tools.
^ Do NOT forcibly bend, twist, or turn the nylon tube.
^ After disconnection, protect the connector end by covering it with a vinyl bag.
^ If the connector is stuck, gently push and pull it to release.
6. Remove the fuel tank filler pipe sub-assembly.
A. Disconnect the fuel tank vent hose (fuel tank inlet pipe side).
Pinch the retainer and pull out the fuel tank vent connector No. 2 with the connector pushed to the pipe side.
B. Disconnect the fuel tank vent hose (fuel tank side) from the clamp.
C. Disconnect the fuel suction tube. Pinch the retainer and pull out the quick connector with the connector pushed to the pipe side.
D. Disconnect the charcoal canister tube No. 1.
Pinch the retainer and pull out the quick connector with the connector pushed to the pipe side.
E. Remove the fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe.
F. Remove the 2 bolts, and then remove the fuel tank filler pipe sub-assembly.
7. Transfer the following parts to the
NEW filler pipe:
^ Fuel inlet box rings
^ Fuel tank filler pipe shield assembly
^ Filler pipe clamps 1 and 2
^ Fuel inlet pipe plate
^ Fuel hose joint
^ Fuel tank gasket
^ Fuel tube connector seal
^ Fuel suction tube set gasket
^ Fuel tank tube
^ Fuel filler pipe clamp
NOTE:
^ Make sure that the fuel inlet seal with retainer are transferred to the NEW fuel filler pipe.
^ Improper installation of the refueling check valve and/or the rollover check valve may result in slow refueling. Refer to the illustrations at the beginning of Repair Procedure 2 for proper installation.
8. Install the NEW fuel tank filler pipe sub-assembly.
A. Install the NEW fuel tank filler pipe sub-assembly.
B. Tighten the 2 bolts.
Torque A:
34 N.m (347 kgf.cm, 25 ft.lbf)
Torque B:
18 N.m (185 kg.cm, 13 ft.lbf)
C. Install the fuel tube connector and fuel filler pipe clamp to the fuel tank inlet pipe.
NOTE:
^ Securely lock the fuel filler pipe clamp.
^ After locking the fuel filler pipe clamp, check that the fuel tube connector is securely installed by pulling the fuel tube in the removal direction.
NOTE:
Before reconnecting each quick connector:
^ Check that there are NO scratches or foreign objects in or around the contact area of the quick connector and pipe.
^ After reconnection, check that the connector is tight by pulling the quick connector in the removal direction.
D. Connect the charcoal canister tube No. 1.
Align the quick connector with the pipe, and then push in the connector until the retainer makes a "click" sound.
E. Connect the fuel suction tube. Align the quick connector with the pipe, and then push in the connector until the retainer makes a "click" sound.
F. Install the fuel tank vent hose (fuel tank side) to the clamp.
G. Connect the fuel tank vent hose (fuel tank inlet pipe side).
Align the fuel tank vent connector No. 2 with the pipe, and then push in the connector until the retainer makes a "click" sound.
9. Install the fuel tank filler pipe protector with the nut.
10. Install the floor under cover No. 1 with the 2 clips and 2 bolts.
11. Install the fuel tank cap assembly.
12. Install the left rear tire.