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Fuel Tank: Service and Repair

REPLACEMENT

CAUTION:
- Always use new gaskets when replacing the fuel tank or component parts.
- Apply the proper torque.

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. DRAIN FUEL
4. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSEMBLY LH (SEPARATED TYPE REAR SEAT)
5. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY (FIXED TYPE REAR SEAT)
6. REMOVE REAR FLOOR SERVICE HOLE COVER NO.2
7. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

NOTE:
- These procedures should be performed with the fuel tank less than 1/4 full.
- Check for dirt 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 in these procedures.
- Do not forcefully bend or twist the nylon tube.
- Check for dirt contamination on the pipe seal surface. Clean if necessary.
- Put the pipe and connector ends in vinyl bags to prevent damage and dirt contamination.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.




a. Disconnect the connector in the fuel tank side.
1. Remove the tube joint clip.
2. Pull out the fuel main tube.
3. Plug the port of the fuel suction plate with a clean rubber cap.




b. Disconnect the connector in the fuel pipe side.
1. Clean the pipe before the operation.
2. Pull out the connector, holding the claw of the retainer by thumb as shown in the illustration.

NOTE: If the connector and the pipe are stuck together, release them by pushing and pulling them by hand.

HINT: Do not remove the retainer when it is reinstalled.

c. Protect each connecting part from damage and contamination by covering it with a vinyl bag.

8. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the fuel sender gauge connector.

9. REMOVE FRONT FLOOR BRACE CENTER
10. REMOVE ENGINE UNDER COVER NO.2
11. REMOVE EXHAUST PIPE ASSEMBLY
12. REMOVE PROPELLER SHAFT HEAT INSULATOR
13. REMOVE FRONT FLOOR HEAT INSULATOR NO.1
a. Remove the 2 bolts and propeller shaft heat insulator.

14. REMOVE DIFFERENTIAL SUPPORT PROTECTOR NO.1
15. REMOVE DIFFERENTIAL SUPPORT PROTECTOR NO.2
16. REMOVE PROPELLER SHAFT ASSEMBLY
17. REMOVE PARKING BRAKE CABLE ASSEMBLY NO.2
18. REMOVE PARKING BRAKE CABLE ASSEMBLY NO.3
19. REMOVE FUEL TANK TO FILLER PIPE HOSE
20. REMOVE FUEL TANK EVAPORATION VENT TUBE
21. REMOVE FUEL TANK BREATHER HOSE
22. REMOVE FUEL TANK ASSEMBLY
a. Using a mission jack, support the fuel tank.
b. Disconnect the fuel tank band No.1 and remove the fuel tank.

23. REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and set plate.

24. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY




a. Lift up the fuel pump and sender gauge. Disconnect the fuel sub-suction hose from the fuel return jet tube, and remove the fuel pump, sender gauge and gasket.

CAUTION:
- Do not damage the fuel pump filter.
- Be careful not to bend the arm of the sender gauge.

25. REMOVE FUEL SENDER GAGE ASSEMBLY
26. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1
27. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY
28. REMOVE CHECK VALVE PROTECTOR




29. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSEMBLY

NOTE:
- When installing or removing the check valve, do not use force. The check valve is made of resin and damages easily. Following these procedures carefully ensures that the check valve stays in good condition and maintains its sealing properties.
- Check valves and gaskets must be replaced with new ones.

a. Insert a clip remover between the check valve and gasket, and remove the check valve pulling up the valve little by little.

30. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSEMBLY
a. Install a new gasket to the fuel tank.
b. Apply some gasoline to the entire circumference of a new over fill check valve, and insert it into the fuel tank without using excessive force. Take care not to drop the gasket into the tank.
c. Confirm that the over fill check valve is inserted without any clearance between the gasket and the lower surface of the valve.

31. INSTALL CHECK VALVE PROTECTOR
32. INSTALL FUEL TANK CUSHION NO.1




a. Attach the fuel tank cushions to the areas marked with diagonal lines in the illustration.

33. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY
34. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1

35. INSTALL FUEL SENDER GAGE ASSEMBLY
a. Inserting a new gasket in between, install the fuel sender gauge.

Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)

36. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY




a. Install a new gasket to the fuel suction plate.
b. Connect the fuel sub-suction hose to the fuel return jet tube.
c. Attach the fuel pump and sender gauge to the fuel tank.

37. INSTALL FUEL TANK VENT TUBE SET PLATE
a. Install the set plate with the 8 bolts.

Torque: 6.0 N.m (61 kgf.cm, 52 in.lbf)

38. INSTALL FUEL TANK ASSEMBLY
a. Install the fuel tank with the fuel tank band.

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

39. INSTALL FUEL TANK BREATHER HOSE
40. INSTALL FUEL TANK EVAPORATION VENT TUBE
41. INSTALL FUEL TANK TO FILLER PIPE HOSE
42. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.3
43. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.2
44. INSTALL PROPELLER SHAFT ASSEMBLY
45. INSTALL DIFFERENTIAL SUPPORT PROTECTOR NO.2
46. INSTALL DIFFERENTIAL SUPPORT PROTECTOR NO.1
47. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
a. Install the front floor heat insulator with the 4 bolts.

Torque: 5.4 N.m (55 kgf.cm, 47 in.lbf)

48. INSTALL PROPELLER SHAFT HEAT INSULATOR
49. INSTALL EXHAUST PIPE ASSEMBLY
50. INSTALL ENGINE UNDER COVER NO.2
51. INSTALL FRONT FLOOR BRACE CENTER
52. INSTALL REAR FLOOR SERVICE HOLE COVER

53. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY




a. Connect the connector on the fuel tank side.
1. Attach the fuel tube connector to the port of the fuel suction plate.
2. Install the tube joint clip.

b. Connect the connector on the fuel pipe side.
1. Insert the connector by aligning the axes of the pipe and the connector until the retainer makes a click sound.

NOTE:
- Check for damage and dirt contamination in the pipe and around the connector.
- After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart.

54. INSTALL REAR FLOOR SERVICE HOLE COVER NO.2
55. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY (FIXED TYPE REAR SEAT)
56. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSEMBLY LH (SEPARATED TYPE REAR SEAT)
57. ADD FUEL
58. CONNECT BATTERY NEGATIVE TERMINAL

NOTE: When disconnecting the negative (-) battery terminal, initialize the following system(s) after the terminal is reconnected.

59. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS
60. CHECK FOR EXHAUST GAS LEAKS
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