Removal and Installation
REMOVAL1. PREVENT GASOLINE FROM SPILLING OUT
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY
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 EXHAUST PIPE ASSEMBLY CENTER
10. DISCONNECT PARKING BRAKE CABLE ASSEMBLY No.2
a. Remove the set bolt and set nut of the parking brake cable assembly No.2.
11. DISCONNECT PARKING BRAKE CABLE ASSEMBLY No.3
a. Remove the set bolt and set nut of the parking brake cable assembly No.3.
12. REMOVE FUEL TANK PROTECTOR LOWER CENTER
a. Remove the 4 bolts and fuel tank protector.
13. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel pump tube.
1. Pinch the tabs 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:
- Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
- It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Do not use any tools in this operation.
- Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
b. Disconnect the fuel tube No.1.
1. Pinch the tube connector and then pull out the fuel tube No.1.
NOTE:
- Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
- It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Do not use any tools in this operation.
- Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
c. Set up a transmission jack underneath the fuel tank.
d. Remove the 2 set bolts of the fuel tank bands.
e. Remove the hose clamp and disconnect the fuel tank to filter pipe hose.
f. Disconnect the fuel tank vent hose from the charcoal canister.
1. Push the connector deep into the charcoal canister to release the locking pin.
2. Pinch portion A.
3. Pull out the connector.
g. Remove the fuel tank.
h. Remove the 2 pins and 2 fuel tank bands as shown in the illustration.
i. Remove the 4 clip nuts.
INSTALLATION
1. INSTALL FUEL TANK ASSEMBLY
a. Install the 4 clip nuts.
b. Install the 2 fuel tank bands with the 2 pins.
c. Connect the fuel tank vent hose.
d. Connect the fuel tank inlet pipe with the fuel filter pipe clamp.
e. Tighten the 2 set bolts of the fuel tank bands.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
f. Connect the fuel tube No.1.
1. Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound.
NOTE:
- Check that there is no damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart.
g. Connect the fuel pump tube.
1. Push in the fuel pump tube connector to the pipe and push up the retainer so that the claws engage.
NOTE:
- Check that there is no damage or foreign objects on the connected part.
- After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart.
2. INSTALL FUEL TANK PROTECTOR LOWER CENTER
a. Install all fuel tank protector lower center.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
3. INSTALL PARKING BRAKE CABLE ASSEMBLY No.3
a. Install the parking brake cable assembly No.3 with the bolt and nut.
Torque:
Bolt:
6.0 N.m (61 kgf.cm, 53 in.lbf)
Nut:
8.5 N.m (87 kgf.cm, 75 in.lbf)
4. INSTALL PARKING BRAKE CABLE ASSEMBLY No.2
a. Install the parking brake cable assembly No.2 with the bolt and nut.
Torque:
Bolt:
6.0 N.m (61 kgf.cm, 53 in.lbf)
Nut:
8.5 N.m (87 kgf.cm, 75 in.lbf)
5. INSTALL EXHAUST PIPE ASSEMBLY CENTER
6. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
7. INSTALL FUEL TANK VENT TUBE SET PLATE
8. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY
9. ADD FUEL
10. CONNECT BATTERY NEGATIVE TERMINAL
11. INSPECT FOR FUEL LEAK
12. INSPECT FOR EXHAUST GAS LEAK
13. INSTALL REAR FLOOR SERVICE HOLE COVER
14. INSTALL REAR SEAT CUSHION ASSEMBLY
15. PERFORM SYSTEM INITIALIZE
a. Some systems need initialization when disconnecting the battery terminal.