Fuel Tank: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE REAR SEAT CUSHION ASSEMBLY (for Coupe)
3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Convertible)
4. REMOVE REAR FLOOR SERVICE HOLE COVER
5. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY
6. REMOVE FUEL TANK VENT TUBE SET PLATE
7. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
8. DRAIN FUEL
9. REMOVE FLOOR PANEL BRACE REAR
10. REMOVE CENTER EXHAUST PIPE ASSEMBLY
a. Remove the 2 bolts, 4 nuts, exhaust pipe and 2 gaskets.
11. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY
a. Remove the set bolt and set nut of the No. 2 parking brake cable.
12. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY
a. Remove the set bolt and set nut of the No. 3 parking brake cable.
13. REMOVE FUEL TANK PROTECTOR LOWER CENTER
a. Remove the 4 bolts and fuel tank protector.
14. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel pump tube.
1. Pinch the tab of the retainer to remove the lock claws and pull it down as shown in the illustration.
2. Pull out the fuel tank main tube.
NOTE:
- Before this operation, check the connector for dirt, mud or other contamination.
- It is necessary to prevent mud or dirt from entering the connector. If mud enters the connectors, the O-rings may not seal properly.
- Disconnect the connector by hand.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe.
b. Disconnect the No. 1 fuel tube.
1. Pinch the tube connector and then pull out the No. 1 fuel tube.
NOTE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
- It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Disconnect the quick connector by hand.
- Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling the connector to release it. Pull the connector off the pipe carefully.
c. Place a transmission jack under the fuel tank assembly.
d. Remove the 2 set bolts of the fuel tank bands (*1).
e. Remove the hose clamp and disconnect the fuel tank to filter pipe hose (*2).
f. Slightly lower the transmission jack.
g. Disconnect the fuel tank vent hose from the charcoal canister (*3).
1. Push the connector deep into the charcoal canister to release the locking pin.
2. Pinch portion A.
3. Pull out the connector.
h. Remove the fuel tank.
i. Remove the 2 pins and 2 fuel tank bands as shown in the illustration.
j. Remove the 4 clip nuts.
15. REMOVE FUEL TANK VENT HOSE
a. Push the connector deep into the charcoal canister to release the locking pin.
b. Pinch portion A.
c. Pull out the connector.
16. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY
a. Remove the fuel pump tube from the fuel main tube support.
17. REMOVE FUEL MAIN TUBE SUPPORT
a. Remove the bolt and tube support.
18. REMOVE NO. 2 FUEL TANK CUSHION
a. Remove the 7 No. 2 fuel tank cushions.
INSTALLATION
1. INSTALL NO. 2 FUEL TANK CUSHION
a. Install 7 new No. 2 fuel tank cushions to the fuel tank.
2. INSTALL FUEL MAIN TUBE SUPPORT
a. Install the fuel main tube support with the bolt.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY
a. Install the fuel pump tube to the fuel main tube support.
4. INSTALL FUEL TANK VENT HOSE
a. Install the fuel tank vent hose.
5. INSTALL FUEL TANK ASSEMBLY
a. Install the 4 clip nuts.
b. Install the 2 fuel tank bands with the 2 pins.
c. Set the fuel tank assembly onto the transmission jack.
d. Raise the transmission jack so that the fuel tank vent hose can be connected (*1).
NOTE: Slowly raise the jack to prevent the fuel tank assembly from dropping.
e. Connect the fuel tank inlet pipe with the fuel filter pipe clamp (*2).
f. Tighten the 2 set bolts of the fuel tank bands (*3).
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
g. Connect the No. 1 fuel tube.
1. Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound.
NOTE:
- Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on any part of the connector.
- After connecting the connector, check if the fuel tube connector and the pipe are securely connected by pulling on them.
h. Connect the fuel pump tube.
1. Push the fuel connector into the pipe and push up the retainer so that the claws engage.
NOTE:
- Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on any part of the connector.
- After connecting the connector, check if the fuel tube connector and the pipe are securely connected by pulling on them.
6. INSTALL FUEL TANK PROTECTOR LOWER CENTER
a. Install the 4 bolts and fuel tank protector.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
7. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY
a. Install the No. 3 parking brake cable assembly with the bolt and nut.
Torque:
Bolt 6.0 N.m (61 kgf.cm, 53 in.lbf)
Nut 5.4 N.m (55 kgf.cm, 48 in.lbf)
8. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY
a. Install the No. 2 parking brake cable assembly with the bolt and nut.
Torque:
Bolt 6.0 N.m (61 kgf.cm, 53 in.lbf)
Nut 5.4 N.m (55 kgf.cm, 48 in.lbf)
9. INSTALL CENTER EXHAUST PIPE ASSEMBLY
a. Install 2 new gaskets and the exhaust pipe with the 2 bolts and 4 new nuts.
Torque: 56 N.m (571 kgf.cm, 41 ft.lbf)
10. INSTALL FLOOR PANEL BRACE REAR
11. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
12. INSTALL FUEL TANK VENT TUBE SET PLATE
13. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY
14. ADD FUEL
15. INSPECT FOR FUEL LEAK
16. INSPECT FOR EXHAUST GAS LEAK
17. INSTALL REAR FLOOR SERVICE HOLE COVER
18. INSTALL REAR SEAT CUSHION ASSEMBLY (for Coupe)
19. INSTALL REAR SEAT CUSHION ASSEMBLY (for Convertible)