Fuel Tank: Service and Repair

REMOVAL

NOTE: Always use "Torx" socket wrench E10 when removing the rear seat.

1. REMOVE REAR SEAT CUSHION COVER PAD (for Hatchback)
2. REMOVE REAR SEAT CUSHION COVER PAD (for Sedan)
3. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for Hatchback)
4. REMOVE DECK BOARD SUB-ASSEMBLY (for Hatchback)
5. REMOVE DECK FLOOR BOX (for Hatchback)
6. REMOVE REAR SEAT LEG COVER NO. 1 (for Hatchback)
7. REMOVE REAR SEAT LEG COVER NO. 2 (for Hatchback)
8. REMOVE REAR SEAT ASSEMBLY (for Hatchback)
9. REMOVE REAR FLOOR SERVICE HOLE COVER
10. DISCHARGE FUEL SYSTEM PRESSURE
11. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
12. DISCONNECT FUEL TANK MAIN TUBE SUBASSEMBLY
13. DISCONNECT FUEL TANK VENT HOSE SUBASSEMBLY
14. REMOVE FUEL PUMP GAUGE RETAINER
15. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
16. DRAIN FUEL




17. REMOVE FRONT FLOOR HEAT INSULATOR NO. 4

a. Remove the 2 nuts together with the insulator.




18. REMOVE FUEL TANK PROTECTOR SUBASSEMBLY

a. Remove the bolt together with the clip.




19. DISCONNECT FUEL TANK MAIN TUBE SUBASSEMBLY

a. Release the lock as shown in the illustration, then pull and remove the fuel tank main tube.

NOTE:
- Remove any dirt and foreign matter from the clip before performing this work.
- Avoid any scratches or foreign matter on the parts when disconnecting them, as the quick 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 parts by covering them with a plastic bag.
- If the connector and pipe are stuck, disconnect the nylon tube by turning it by hand to release them.




20. DISCONNECT FUEL TANK BREATHER HOSE

a. Release the lock as shown in the illustration, then pull and remove the fuel tank breather hose.

NOTE:
- Remove any dirt and foreign matter from the clip before performing this work.
- Avoid any scratches or foreign matter on the parts when disconnecting, as the quick 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 parts by covering them with a plastic bag.
- If the connector and pipe are stuck, disconnect the nylon tube by turning it by hand to release them.




21. DISCONNECT FUEL TANK FILLER PIPE SUBASSEMBLY LOWER

a. Loosen the clamp and disconnect the fuel tank filler pipe.




22. REMOVE FUEL TANK ASSEMBLY

a. Remove the 4 bolts and remove the fuel tank.




b. Remove the fuel tank main tube from the fuel tank.

INSTALLATION

NOTE: Always use "Torx" socket wrench E10 when removing the rear seat.




1. INSTALL FUEL TANK ASSEMBLY

a. Install the fuel tank main tube onto the fuel tank.
b. Clean the bolt hole and remove any grease.




c. Install the fuel tank with 4 new bolts.

Torque: 14 Nm (146 kgf.cm, 10 ft. lbs.)




2. CONNECT FUEL TANK FILLER PIPE SUBASSEMBLY LOWER

a. Connect the fuel tank filler pipe and install the clamp.




3. CONNECT FUEL TANK BREATHER TUBE

a. Align the fuel tank breather tube connector with the pipe, push the fuel tube connector in until the retainer makes a click sound, then lock the cover of the connector.

NOTE:
- Check that there are no scratches or foreign matter on the disconnected parts of the fuel tank breather tube connector and pipe before performing this work. "
- After connecting, pull the pipe and fuel tank breather connector to make sure that they are securely connected.




4. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

a. Align the fuel tube connector with the pipe, push the fuel tube connector in until the retainer makes a click sound, then lock the cover of the connector.

NOTE:
- Check that there are no scratches or foreign matter on the disconnected parts of the fuel tube connector and pipe before performing this work.
- After connecting, pull the pipe and fuel tube connector to make sure that they are securely connected.




5. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY

a. Install the fuel tank protector sub-assembly with the bolt and clip.

Torque: 5.4 Nm (55 kgf.cm, 48 in. lbs.)




6. INSTALL FRONT FLOOR HEAT INSULATOR NO. 4

a. Install the 2 nuts.

Torque: 5.4 Nm (55 kgf.cm, 48 in. lbs.)

7. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
8. INSTALL FUEL PUMP GAUGE RETAINER
9. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY
10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
11. CONNECT REAR FLOOR SERVICE HOLE COVER
12. INSTALL REAR SEAT ASSEMBLY (for Hatchback)
13. INSTALL REAR SEAT LEG COVER NO. 2 (for Hatchback)
14. INSTALL REAR SEAT LEG COVER NO. 1 (for Hatchback)
15. INSTALL DECK FLOOR BOX (for Hatchback)
16. INSTALL DECK BOARD SUB-ASSEMBLY (for Hatchback)
17. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Hatchback)
18. INSTALL REAR SEAT CUSHION COVER PAD (for Sedan)
19. INSTALL REAR SEAT CUSHION COVER PAD (for Hatchback)
20. ADD FUEL
21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque: 5.4 Nm (55 kgf.cm, 48 in. lbs.)

22. CHECK FOR FUEL LEAKAGE