Fuel Tank: Service and Repair

FUEL TANK REMOVAL/INSTALLATION [L5]

WARNING:
- Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
- Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
- A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

CAUTION:
- Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1. Level the vehicle.

2. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution

3. Disconnect the negative battery cable. Removal and Replacement

4. Remove the rear seat cushion. Rear Seat Removal/Installation

5. Remove the service hole cover.






6. Disconnect the quick release connector connected to the fuel pump unit. Quick Release Connector Removal/Installation






7. Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.

8. Drain the fuel from the fuel tank using the following procedure:

Using M-MDS
- Connect the negative battery cable. Removal and Replacement
- Connect the M-MDS to the DLC-2.





- Switch the ignition to ON.
- Using the simulation function "FP", start the fuel pump. On-Board Diagnostic Test

Without using M-MDS
- Remove the fuel pump relay.






CAUTION:
- Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.

- Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.





- Connect the negative battery cable and operate the fuel pump. Removal and Replacement

CAUTION:
- The fuel pump could be damaged if it is operated while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

9. Stop the fuel pump using the following procedure.

Using M-MDS
- Using the simulation function "FP", stop the fuel pump. On-Board Diagnostic Test
- Disconnect the negative battery cable. Removal and Replacement

Without using M-MDS
- Disconnect the negative battery cable to stop the fuel pump. Removal and Replacement
- Disconnect the jumper wire.

10. Remove the fuel pump unit. (See Removal and Replacement.)

11. Remove the fuel gauge sender unit. (See Service and Repair.)

12. Remove the TWC. (See Service and Repair.)

13. Remove the rear under cover (LR, RR).

14. Remove the rear parking brake cable installation bolts, then move the rear parking brake cable out of the way.

15. Disconnect the joint hose connected between the fuel tank and the fuel-filler pipe from the fuel-filler pipe.

16. Disconnect the breather hose connected between the fuel tank and the fuel-filler pipe from the fuel-filler pipe.

17. Disconnect the evaporative hose connected between the fuel tank and the charcoal canister from the charcoal canister.

18. Disconnect the fuel tank pressure sensor connector.

19. Remove in the order indicated in the table









20. Install in the reverse order of removal.

21. Complete the "AFTER SERVICE PRECAUTION". (See After Service Precaution.)

Rivet Removal Note

CAUTION:
- Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.

NOTE:
- The insulator is installed using rivets.
- When resin stalling the rivet, install the same rivet or M5 bolt and nut.

1. Push out the mandrel using a hammer and punch (2-2.8 mm {0.08-0.11 in} diameter).






2. Remove the flange using a drill (5 mm {0.20 in} drill bit).





Fuel-filler Pipe Removal Note

1. Remove the rear tire (LH).

2. Remove the fuel pipe protector.

3. Remove the air filter.

4. Remove the fuel-filler pipe.

Breather Hose Installation Note

1. Install the breather hose and clamp as shown in the figure.






Joint Hose Installation Note

1. Install the joint hose and clamp as shown in the figure.