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FUEL TANK REMOVAL/INSTALLATION

BHE011442110W01

  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.

1. Park the vehicle on a level surface.

2. Perform the fuel line safety procedure referring to the before repair procedure. (See BEFORE REPAIR PROCEDURE.)

3. Remove the rear seat. (See REAR SEAT REMOVAL/INSTALLATION.)

4. Drain fuel from the fuel tank.

  Warning

  • 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 a vehicle.

  Caution

  • When the fuel gauge indicates 3/4 or more, the fuel level is higher than the installation surface of the fuel pump and the fuel suction pipe bracket. Due to this condition, fuel may spill or leak out when performing this procedure. Before performing this procedure, always drain out fuel so that the fuel tank is half full or less (according to the fuel gauge needle).

  (1) Disconnect the quick release connector (engine compartment side). (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.)
  (2) Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
  (3) Ground check connector terminal F/P to the body using a jumper wire.

> > Caution

>   • Shorting the wrong terminal of the check connector may cause malfunctions. Make sure to short only the specified terminal.

  (4) Turn the ignition switch to the ON position and operate the fuel pump for approx. 20 min.

> > Caution

>   • The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged.

  (5) When essentially no fuel is being discharged from the hose, turn the ignition switch to the LOCK position.

  Note

  • When operating the fuel pump with a full fuel tank, fuel discharge will become erratic after approx. 10 min but will continue for approx. 10 min more and then essentially no fuel will be discharged. At this time the fuel gauge needle will be at the halfway position.

  (6) Disconnect the jumper wire.
  (7) Disconnect the negative battery cable.

5. Remove the following parts:

  (1) Fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION.)
  (2) Main silencer and middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION.)
  (3) Power plant frame. (See TRANSMISSION REMOVAL/INSTALLATION [R15M-D].) (See TRANSMISSION REMOVAL/INSTALLATION [Y16M-D].) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION.)
  (4) Propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

6. Position the parking brake cable out of the way. (See PARKING BRAKE LEVER REMOVAL/INSTALLATION.)

7. Remove in the order indicated in the table.

8. Install in the reverse order of removal.

9. Inspect all parts by performing the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE.)

1 | Connector
2 | Evaporative hose (See Rollover Valve.)
3 | Breather hose (See Fuel Shut-off Valve.)
4 | Joint hose (See Joint Hose Installation Note.)
5 | Strap
6 | Fuel tank
7 | Cap (See Cap Removal Note.) (See Cap Installation Note.)
8 | Fuel suction pipe bracket
9 | Fuel suction hose
10 | Fuel suction pipe
11 | Protector
12 | Joint pipe (See Fuel Tank Side (Except for Fuel Shut-off/Rollover Valve).)
13 | Dust cover
14 | Fuel-filler pipe (See Fuel-filler Pipe Removal Note.)
15 | Retainer

## Cap Removal Note

  Caution

  • The cap could be damaged if the SST is used with any play between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

1. Remove the cap using the SST.

## Fuel-filler Pipe Removal Note

1. Remove the rear ABS wheel-speed sensor. (See REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

2. Remove the rear shock absorber lower bolt. (See REAR SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION.)

3. Loosen the rear crossmember installation nut (6 locations), and lower the rear crossmember. (See REAR CROSSMEMBER REMOVAL/INSTALLATION.)

4. Remove the fuel-filler pipe.

## Cap Installation Note

1. Align the alignment mark of the fuel suction pipe bracket and the retainer notch as shown in the figure.

2. Align the positions of the cap and retainer as shown in the figure, and tighten them one full rotation by hand.

  • If the retainer and cap cannot be tighten by hand, remove the cap, verify that there is no damage or misalignment on the retainer and cap, and then tighten again.

  Caution

  • The cap could be damaged if the SST is used with any play between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

3. While keeping the alignment mark and the retainer notch aligned, tighten the cap to the rotation angle and specified torque using the SST.

  • If the specified torque cannot be obtained even when the cap is rotated to the specified rotation angle, replace with a new cap and retainer and repeat Step 3.

  Rotation angle
  50-140°
  (Total angle for Step 2 and Step 3 is 410-500°.)
  Cap tightening torque
  80-135 N·m {8.2-13.7 kgf·m, 59-99 ft·lbf}

## Joint Hose Installation Note

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