Fuel Tank: Service and Repair
Removal & Installation and Disassembly & Reassembly1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE REAR SEAT CUSHION ASSEMBLY RH
3. REMOVE REAR FLOOR SERVICE HOLE COVER
4. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY.
5. DRAIN FUEL
6. REMOVE CONSOLE BOX ASSEMBLY REAR (2ZZ-GE ENGINE TYPE).
7. REMOVE EXHAUST PIPE ASSEMBLY 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, then pull the connector to the outside of the vehicle.
e. Disconnect the heated oxygen sensor connector.
f. Remove the grommet, then pull the connector to the outside of the vehicle.
g. Remove 2 nuts and the floor panel brace front.
h. Remove the 4 bolts and 4 compression springs.
i. Remove the exhaust pipe front from the 2 exhaust pipe supports No. 4.
j. Remove the gasket from the exhaust manifold.
k. Remove the gasket from the exhaust pipe front.
8. REMOVE FUEL TANK PROTECTOR NO.1
a. Remove the 4 bolts, then remove the fuel tank protector No. 1.
9. DISCONNECT PARKING BRAKE CABLE ASSEMBLY NO.2
a. Remove the 2 bolts, then disconnect the parking brake cable No. 2.
10. DISCONNECT PARKING BRAKE CABLE ASSEMBLY NO.3
a. Remove the 2 bolts, then disconnect the parking brake cable No. 3.
11. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel tank main tube.
1. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and push it down as shown in the illustration.
2. Pull the fuel tank main tube out of the pipe.
NOTE:
- Remove any dirt or foreign objects on the fuel tube connector before performing 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 disconnected part by covering it with a vinyl bag after disconnecting the fuel tank main tube.
- If the fuel tube connector and pipe are stuck, push and pull them to release.
b. Disconnect the fuel tank breather tube.
1. Remove the checker of the fuel tube connector from the pipe.
2. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.
NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing 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 disconnected part by covering it with a vinyl bag after disconnecting the fuel tank breather tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
c. Disconnect the fuel tank vent hose.
1. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and slide it as shown in the illustration.
2. Pull the fuel tank vent hose out of the pipe.
NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing 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 plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tank vent hose.
d. Using a screwdriver, unfasten the claw. Then remove the fuel tank filler pipe cover from the fuel tank filler pipe.
e. Loosen the hose clamp bolt, then disconnect the fuel tank filler pipe hose from the fuel tank.
f. Hold the fuel tank using a transmission jack.
g. Remove the 4 bolts, then remove the 2 fuel tank bands No. 1.
h. Operate the transmission jack, then remove the fuel tank.
12. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Remove the fuel tank main tube from the fuel tank.
13. REMOVE FUEL TANK VENT HOSE
a. Remove the fuel vent hose from the fuel tank clamp.
14. REMOVE FUEL TANK CUSHION NO.1
a. Remove the 4 fuel tank cushions No. 1 from the fuel tank.
15. INSTALL FUEL TANK CUSHION NO.1
a. Install 4 new fuel tank cushions No. 1 onto the fuel tank.
16. INSTALL FUEL TANK VENT HOSE
a. Install the fuel onto the fuel tube clamp.
17. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Install the fuel tank main tube onto the fuel tank.
18. INSTALL FUEL TANK ASSEMBLY
a. Set the fuel tank on a transmission jack.
b. Operate the transmission jack, then install the fuel tank into the vehicle.
c. Install the 2 fuel tank bands No. 1 with the 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
d. Connect the fuel tank to filler pipe hose to the fuel tank
NOTE: Make sure that the hose clamp is at the correct direction when installing.
e. Align the claw position, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
f. Connect the fuel tank vent hose.
1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
2. Slide the retainer of the fuel tube connector to the claws lock as shown in the illustration.
NOTE:
- Check that the there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tube connector.
g. Connect the fuel tank breather tube.
1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank breather 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 performing this work.
- After connecting the fuel tank breather tube, check that the fuel pump tube is securely connected by pulling the fuel tube connector and pipe.
2. Install the checker onto the pipe.
h. Connect the fuel tank main tube
1. Align the fuel tube connector with the pipe, then push the fuel tube connector into until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling the fuel tube connector and pipe.
19. CONNECT PARKING BRAKE CABLE ASSEMBLY NO.3
a. Align the turn prevention positions, then connect the parking brake cable No. 3 with the 2 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
20. CONNECT PARKING BRAKE CABLE ASSEMBLY NO.2
a. Align the turn prevention positions, then connect the parking brake cable No. 2 with the 2 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
21. INSTALL EXHAUST PIPE ASSEMBLY FRONT
a. Check the free length.
1. Using vernier calipers, measure the free length of the compression spring.
Minimum:
41.5 mm (1.6339 in.) for exhaust manifold side
38.5 mm (1.5158 in.) for exhaust pipe tail side
If the free length is less than minimum, replace the compression spring.
b. Using a wooden block and plastic-faced hammer, tap a new gasket into the exhaust manifold.
NOTE:
- Make sure that the gasket is in the correct direction when installing.
- Do not reuse a removed gasket.
- Never push the gasket into the exhaust manifold by installing the exhaust pipe front onto the exhaust manifold.
c. Using a wooden block and plastic-faced hammer, tap a new gasket into the exhaust tail.
NOTE:
- Make sure that the gasket is in the correct direction when installing.
- Do not reuse a removed gasket.
- Never push the gasket into the exhaust manifold by installing the exhaust pipe front onto the exhaust exhaust tail.
d. Install the exhaust pipe front onto the 2 exhaust pipe supports No. 4.
e. Tighten the 4 compression springs and 4 bolts.
Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)
f. Install the floor panel brace front with 2 nuts.
Torque: 30 N.m (302 kgf.cm, 22 ft.lbf)
g. Pull the connector back inside the vehicle, then install the grommet.
h. Connect the heated oxygen sensor connector.
i. Pull the connector back inside the vehicle, then install the grommet.
j. Connect the heated oxygen sensor connector.
k. Install the floor carpet front with the clip.
22. INSTALL CONSOLE BOX ASSEMBLY REAR
23. ADD FUEL
24. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY
25. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
26. CHECK FOR FUEL LEAKAGE
NOTE: Check for fuel leakage with the fuel pump connector connected.
27. CHECK FOR EXHAUST GAS LEAKAGE
28. INSTALL REAR FLOOR SERVICE HOLE COVER
29. INSTALL FUEL TANK PROTECTOR NO.1
a. Install the fuel tank protector No. 1 with the 4 bolts
30. INSTALL REAR SEAT CUSHION ASSEMBLY RH