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Fuel Tank: Service and Repair

FUEL TANK ASSY (FF)

Fuel Tank Assy (FF) Part 1:




Fuel Tank Assy (FF) Part 2:




Fuel Tank Assy (FF) Part 3:






Removal & Installation and Disassembly & Reassembly

1. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY
2. REMOVE REAR FLOOR SERVICE HOLE COVER
3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
a. Start the engine.
b. After the engine has stopped on the its own, turn the ignition switch to lock.

4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY
5. DISCONNECT FUEL EMISSION TUBE SUB-ASSY NO.1
6. REMOVE FUEL TANK VENT TUBE SET PLATE
7. REMOVE FUEL PUMP ASSEMBLY
8. REMOVE FUEL SUCTION TUBE SET GASKET
9. DRAIN FUEL




10. REMOVE CONSOLE BOX ASSY REAR (2ZZ-GE ENGINE TYPE)
a. Remove the console box insert.
b. Remove the console box damper.
c. Remove the 4 bolts.
d. Disconnect the power point socket connector, and remove the console box.




11. REMOVE FLOOR PANEL BRACE FRONT
Remove the 2 nuts and floor panel brace front.




12. REMOVE EXHAUST PIPE ASSY FRONT
a. Using a clip remover, remove the clip.
b. Tear off the front floor carpet.

c. 1ZZ-FE:
Disconnect the oxygen sensor connector.

d. 2ZZ-GE:
Disconnect the 2 oxygen sensor connectors.

e. Remove the 2 exhaust pipe supports.




f. Remove the 4 bolts, 4 compression springs and exhaust pipe.




13. REMOVE FUEL TANK PROTECTOR NO.1
Remove the 5 bolts and fuel tank protector.




14. SEPARATE PARKING BRAKE CABLE ASSY NO.2
Remove the 2 installing bolts of the parking brake cable.




15. SEPARATE PARKING BRAKE CABLE ASSY NO.3
Remove the 2 installing bolts of the parking brake cable.




16. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY
a. Pinch the fuel tube connector clip, and remove the fuel tube connector clip.
b. Pull out the fuel tank main tube.

NOTE:
- Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
- Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.




- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- After disconnecting, cover the fuel tube connector with a vinyl bag.
- When the fuel tube connector and pipe are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.




17. DISCONNECT FUEL TANK INLET PIPE FUEL HOSE
Disconnect the fuel tank inlet filler pipe hose from the fuel tank.




18. DISCONNECT FUEL TANK BREATHER HOSE
Disconnect the fuel tank breather hose from the fuel tank.




19. DISCONNECT FUEL TANK VENT HOSE
Disconnect the fuel tank bent hose from the charcoal canister.
1. Push the connector deep inside.
2. Pinch portion A.
3. Pull out the connector.




20. DISCONNECT VALVE TO FUEL FILLER PIPE HOSE
Disconnect the valve to fuel filler pipe hose from the fuel tank inlet pipe.




21. DISCONNECT FUEL EMISSION TUBE SUB-ASSY NO.1
Pinch the fuel tube connector clip and then pull out the fuel emission tube.

NOTE:
- Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
- Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.




- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- After disconnecting, cover the fuel tube connector with a vinyl bag.
- When the fuel tube connector and pipe are stuck, pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.




22. REMOVE FUEL TANK ASSY
a. Set a mission jack to the fuel tank.
b. Remove the 4 bolts, 2 fuel tank bands and fuel tank.




23. REMOVE FUEL TANK MAIN TUBE SUB-ASSY
Remove the fuel tank main tube from the fuel tube clamp and bracket.




24. REMOVE FUEL TUBE CLAMP NO.4
Remove the bolt and fuel tank clamp.




25. REMOVE FUEL TUBE BRACKET
Remove the fuel tube bracket from the fuel tank.




26. REMOVE FUEL EMISSION TUBE SUB-ASSY NO.1
Pinch the fuel tube connector clip and then pull out the fuel emission tube.

NOTE:
- Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
- Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
- Do not use any tool in this work.




- Do not bend or twist the nylon tube by force.
- After disconnecting, cover the fuel tube connector with a vinyl bag.
- When the fuel tube connector and pipe are stuck, pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.




27. REMOVE FUEL TUBE CLAMP NO.2
Remove the fuel tube clamp from the fuel tank.




28. REMOVE CHECK VALVE PROTECTOR
Using a screwdriver, unlock the claw, and remove the check valve protector by turning it counter clockwise.




29. REMOVE FUEL TANK INLET VALVE ASSY
Insert a clip remover between the fuel tank inlet valve and gasket, remove the fuel tank inlet valve by gradually pushing it upward.

NOTE:
- Work accurately to maintain the sealing performance of the fuel tank inlet valve, since it is made from resin. It is easy to damage by removing and installing forcibly.
- Be sure to install a new fuel tank inlet valve and gasket.




30. REMOVE CHECK VALVE GASKET
Remove the gasket from the fuel tank inlet valve.




31. REMOVE FUEL TANK CUSHION NO.1
Remove the 7 fuel tank cushions from the fuel tank.




32. INSTALL FUEL TANK CUSHION NO.1
Install the 7 new fuel tank cushions to the fuel tank.




33. INSTALL CHECK VALVE GASKET
Install a new gasket to the fuel tank.




34. INSTALL FUEL TANK INLET VALVE ASSY
Apply a light coat of oil around the fuel tank inlet valve as shown in the illustration, and insert it into the fuel tank without force.

NOTE: Be careful not to drop the gasket into the fuel tank.

35. INSTALL FUEL EMISSION TUBE SUB-ASSY NO.1
Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound.

NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the pipe and fuel tube connector are securely connected by pulling them.

36. INSTALL FUEL TUBE CLAMP NO.4
Install the fuel tube clamp with the bolt.

Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)

37. INSTALL FUEL TANK ASSY
a. Set a mission jack to the fuel tank.
b. Install the fuel tank and 2 fuel tank bands with the 4 bolts.

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

38. CONNECT FUEL EMISSION TUBE SUB-ASSY NO.1
Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound.

NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.

39. CONNECT FUEL TANK MAIN TUBE SUB-ASSY
Push in the fuel tube connector to pipe until fuel tube connector, and install the fuel tube connector clip.

NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.

40. INSTALL PARKING BRAKE CABLE ASSY NO.3
Install the parking brake cable with the 2 bolts.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

41. INSTALL PARKING BRAKE CABLE ASSY NO.2
Install the parking brake cable with the 2 bolts.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

42. INSTALL FUEL TANK PROTECTOR NO.1
Install the fuel tank protector with the 5 bolts.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)




43. INSTALL EXHAUST PIPE ASSY FRONT
a. Using vernier calipers, measure the free length of the compression spring.

Free length:

Front side 43 mm (1.6929 in.)
Rear side 40 mm (1.5748 in.)

b. Using a hammer and wooden block, tap in a new gasket until its surface is flush with the exhaust manifold.

NOTE:
- Tap in the gasket in the correct direction.
- Do not reuse the removed gasket.
- Be sure not to push in the gasket by installing the exhaust pipe.




c. Install a new gasket on the exhaust pipe (rear side).
d. Install the exhaust pipe with the 4 compression springs and 4 bolts.

Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)

e. Install the 2 exhaust pipe supports.
f. 1ZZ-FE:
Connect the oxygen sensor connector.

g. 2ZZ-GE:
Connect the 2 oxygen sensor connectors.

h. Install the font floor carpet with a clip.

44. INSTALL FLOOR PANEL BRACE FRONT
Install the floor panel brace front with the 2 nuts.

Torque: 30 N.m (302 kgf.cm, 22 ft.lbf)

45. INSTALL FUEL SUCTION TUBE SET GASKET
46. INSTALL FUEL PUMP ASSEMBLY
47. INSTALL FUEL TANK VENT TUBE SET PLATE
48. CONNECT FUEL EMISSION TUBE SUB-ASSY NO.1
49. CONNECT FUEL TANK MAIN TUBE SUB-ASSY
50. CHECK FUEL LEAK
51. CHECK EXHAUST GAS LEAK
52. INSTALL REAR FLOOR SERVICE HOLE COVER
53. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY
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