Fuel Tank: Service and Repair

REMOVAL
1. Relieve fuel pressure in fuel feed line referring to "Engine General Information and Diagnosis".
2. Disconnect negative (-) cable at battery.
3. before disconnecting fuel filler hose, give match marks on fuel filler hose and fuel filler neck.




4. Disconnect fuel filler hose from fuel filler neck.
5. Insert hose of a hand operated pump into fuel filler hose and drain fuel in space in the figure (drain fuel through it till fuel stops).

CAUTION: Do not force hose of a hand operated pump into fuel tank. Doing so can damage inlet valve.




6. Remove fuel tank filler hose protector.
Disconnect filler hose from fuel tank and breather hose from fuel filler neck.
7. Remove fuel tank inlet valve Use care not to damage inlet valve when removing
8. Drain fuel tank by pumping fuel out through fuel tank filler. Use hand operated pump device to drain fuel tank.




9. Disconnect fuel filter inlet hose from filter.




10. Disconnect fuel check valve hose (1) and return hose (2) and vapor control outlet hose (3) from pipes
11. Remove fuel tank protector from vehicle




12. Lower fuel tank gradually while holding it horizontally and pull out each coupler from fuel pump (1) and fuel tank pressure sensor (2)

INSTALLATION
1. Install fuel pump assembly, fuel cut valve and vapor control valve to fuel tank. Refer to "FUEL PUMP".




2. Connect fuel hoses to fuel tank, fuel cut valve, and vapor control valve, check valve and fuel pump assembly. After connecting, clamp hoses securely.
3. Install inlet valve to fuel tank. If deformed or damaged in any other way, replace with a new one
4. Install fuel tank by using fuel tank belts and then install protector to vehicle.

Tightening torque
Fuel tank bolt (a) : 50 N.m (5.0 kg-m, 36.5 lb-ft)
Fuel tank protector bolt (a): 50 N.m (5.0 kg-m, 36.5 lb-ft)

5. Connect fuel filler hose to fuel filler neck with match the match marks. And then clamp the securely.
6. Connect fuel filler hose to fuel tank and breather hose to fuel filler neck. Clamp them securely.

Tightening torque
Breather hose clamp (b) : 2.0 N.m (0.2 kg-m, 2.0 lb-ft)
Fuel filler hose clamp (c) : 4.0 N.m (0.4 kg-m, 3.0 lb-ft)

7. Install fuel filler hose protector.




8. Connect check valve hose (1), return hose (2) and vapor control valve outlet hose (3) to fuel pipe. And clamp them securely.




9. Connect fuel filter inlet hose to fuel filter.
10. Connect coupler to fuel pump assembly and tank pressure sensor respectively.
11. Connect negative (-) cable to battery.
12. Upon completion of Installation, check fuel system for leakage.