FUEL TANK REMOVAL/INSTALLATION [LF]
| WARNING | Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to "BEFORE SERVICE PRECAUTION". Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit removal/installation, always complete the "Fuel Leak Inspection After Fuel Pump Unit Installation". 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. |
Scheme 26
Scheme 27
- Park the vehicle on a level surface.
- Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-430308-S13106615682011101700000) .)
- Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) .)
- Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) .)
- Remove the following parts. Middle pipe (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [LF]»(ref-430331-S12243692342011101700000) .) Propeller shaft (See «PROPELLER SHAFT REMOVAL/INSTALLATION»(ref-430351-S24481708432011101700000) .) Power plant frame (See «TRANSMISSION REMOVAL/INSTALLATION [M15M-D]»(ref-430321-S20208983802011101700000) .) (See «TRANSMISSION REMOVAL/INSTALLATION [P66M-D]»(ref-430322-S39125528952011101700000) .) (See «AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [SJ6A-EL]»(ref-430333-S25457889692011101700000) .) Rear drive shaft (See «REAR DRIVE SHAFT REMOVAL/INSTALLATION»(ref-430302-S07472880362011101700000) .) Rear differential (See «REAR DIFFERENTIAL REMOVAL/INSTALLATION»(ref-430335-S15360136942011101700000) .) Rear crossmember component (See «REAR CROSSMEMBER REMOVAL/INSTALLATION»(ref-430352-S19760319882011101700000) .)
- Perform the following procedure to remove the service hole cover. To remove the back trim, remove the following parts: Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-430296-S42659527912011101700000) .) Quarter trim (See «QUARTER TRIM REMOVAL/INSTALLATION»(ref-430296-S19001214662011101700000) .) Scuff plate (See «SCUFF PLATE REMOVAL/INSTALLATION»(ref-430296-S23280190182011101700000) .) Tire house trim (See «TIRE HOUSE TRIM REMOVAL/INSTALLATION»(ref-430296-S18767630022011101700000) .) Aeroboard (See «AEROBOARD REMOVAL/INSTALLATION»(ref-430296-S39585070462011101700000) .) Front seat bar garnish (See «SEAT BACK BAR GARNISH REMOVAL/INSTALLATION»(ref-430296-S00744916912011101700000) .) Remove the back trim. (See «BACK TRIM REMOVAL/INSTALLATION»(ref-430296-S24537138642011101700000) .) Remove the service hole cover.
- Disconnect the quick release connector using the SST from the fuel pump unit. (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [LF]»(ref-430308-S31748830442011101700000) .)
- Remove the fuel pump unit. (See «FUEL PUMP UNIT REMOVAL/INSTALLATION [LF]»(ref-430308-S01516958942011101700000) .)
- Siphon the fuel from the fuel tank.
- Remove in the order indicated in the table.
- Install in the reverse order of removal.
- Complete the "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF]»(ref-430308-S11387419382011101700000) .)
Protector Removal Note
- Remove the trunk side trim. (See «TRUNK SIDE TRIM REMOVAL/INSTALLATION»(ref-430296-S12262640872011101700000) .)
Fuel Tank Removal Note
- Move the dust cover slightly out of the way.
- Move the charcoal canister slightly out of the way. (See «CHARCOAL CANISTER REMOVAL/INSTALLATION [LF]»(ref-430327-S40932760142011101700000) .)
Insulator 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 reinstalling the rivet, install the same rivet or M5 bolt and nut.
Scheme 28
- Push out the mandrel using a hammer and punch (2-2.8 mm {0.08-0.11 in} diameter).
- Remove the flange using a drill (5 mm {0.20 in} drill bit).
Scheme 29
Scheme 30
Scheme 30: Breather Hose Installation Note
- Install the breather hose and clamp as shown in the illustration.
Scheme 31
Scheme 31: Joint Hose Installation Note
- Install the joint hose and clamp as shown in the illustration.
- Install the clamp between the spool and stopper without overlapping the stopper.
FUEL PUMP UNIT REMOVAL/INSTALLATION [LF]
| WARNING | Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to "BEFORE SERVICE PRECAUTION". Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit removal/installation, always complete the "Fuel Leak Inspection After Fuel Pump Unit Installation". |
Scheme 32
Scheme 33
- Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-430308-S13106615682011101700000) .)
- Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) .)
- Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) .)
- Perform the following procedure to remove the service hole cover. To remove the back trim, remove the following parts: Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-430296-S42659527912011101700000) .) Quarter trim (See «QUARTER TRIM REMOVAL/INSTALLATION»(ref-430296-S19001214662011101700000) .) Scuff plate (See «SCUFF PLATE REMOVAL/INSTALLATION»(ref-430296-S23280190182011101700000) ) Tire house trim (See «TIRE HOUSE TRIM REMOVAL/INSTALLATION»(ref-430296-S18767630022011101700000) .) Aeroboard (See «AEROBOARD REMOVAL/INSTALLATION»(ref-430296-S39585070462011101700000) .) Front seat back bar garnish (See «SEAT BACK BAR GARNISH REMOVAL/INSTALLATION»(ref-430296-S00744916912011101700000) .) Remove the back trim. (See «BACK TRIM REMOVAL/INSTALLATION»(ref-430296-S24537138642011101700000) .) Remove the service hole cover.
- Disconnect the quick release connector from the fuel pump unit. (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [LF]»(ref-430308-S31748830442011101700000) .)
- Disconnect the fuel pump unit connector.
- Remove in the order indicated in the table.
- Install in the reverse order of removal.
- Complete the "AFTER SERVICE PRECAUTION" (See «AFTER SERVICE PRECAUTION [LF]»(ref-430308-S11387419382011101700000) .)
QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [LF]
| WARNING | Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION". |
Scheme 34
Scheme 34: Quick Release Connector Type
Scheme 35
Scheme 35: Type A Removal
Scheme 36
Scheme 37
- Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-430308-S13106615682011101700000) .) CAUTION: The quick release connector may be damaged if the release tab is bent excessively. Do not expand the release tab over the stopper. NOTE: The fuel hose can be removed by pushing it to the pipe side to release the lock.
- Rotate the release tab on the quick release connector to the stopper position.
- Pull out the fuel hose straight from the fuel pipe and disconnect it.
- Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from becoming scratched or dirty.
Type B Removal
| CAUTION | Be careful not to damage the pipe when unlocking the retainer. |
Note. When removing the quick connector, either SST 49 E042 001 or 49 N013 103A (Part of 49 N013 1A0D ) can be used.
Scheme 38
Scheme 38: When using SST 49 N013 103A (Part of 49 N013 1A0D)
- Follow "BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-430308-S13106615682011101700000) .)
- Insert the SST into the quick release connector.
- Pull out the fuel hose straight from the fuel pipe and disconnect it.
- Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.
Type A Installation
Note. If the quick release connector O-ring is damaged or has slipped, replace the fuel hose. A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.
Scheme 39
Scheme 39: Type A Installation
- Inspect the fuel hose and fuel pipe sealing surface for damage and deformation. If there is any malfunction, replace it with a new one.
- Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
- Reconnect the fuel hose straight to the fuel pipe until a click is heard. NOTE: If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.
- Lightly pull and push the quick release connector a few times by hand, and then verify that it can move 2.0-3.0 mm {0.08-0.12 in} and is connected securely.
- Complete the "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF]»(ref-430308-S11387419382011101700000) .)
Type B Installation
| CAUTION | Always replace the retainer with a new one when using SST 49 E042 001, otherwise, fuel leakage could result. |
Note. If the quick release connector O-ring is damaged or has slipped, replace the piping component. A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.
Scheme 40
- Inspect the fuel hose and fuel pipe sealing surface for damage and deformation. If there is any malfunction, replace it with a new one.
- Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
- Install a new retainer to the quick release connector.
- Reconnect the hose straight to the pipe until a click is heard.
- Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.
- Complete the "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF]»(ref-430308-S11387419382011101700000) .)
FUEL INJECTOR REMOVAL/INSTALLATION [LF]
| WARNING | Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION". |
Scheme 41
- Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-430308-S13106615682011101700000) .)
- Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]»(ref-430300-S30731392202011101700000) .)
- Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) .)
- Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) .)
- Disconnect the fuel injector connector and move the harness slightly out of the way.
- Remove in the order indicated in the table.
- Install in the reverse order of removal.
- Complete the "AFTER SERVICE PRECAUTION" (See «AFTER SERVICE PRECAUTION [LF]»(ref-430308-S11387419382011101700000) .)
Fuel Injector Removal Note
| CAUTION | Use of a deformed injector clip will cause the fuel injector to be connected incorrectly and could result in fuel leakage. It will also cause the injector to rotate. Therefore, always replace the clip when the injector is removed. |
Scheme 42
Scheme 43
Scheme 44
- Insert a flathead screwdriver between the injector cup and clip finger. NOTE: When pushing the clip finger outward, deform the finger until it is removed completely from the cup notch.
- Push the clip finger outward using a flathead screwdriver.
- Remove the injector with the clip.
- Remove the clip from the fuel injector using the following procedure: NOTE: The clip will not be reused. Hold the clip using pliers. Pull the clip parallel to the injector groove and remove it from the injector.
Scheme 45
Scheme 45: Fuel Injector Installation Note
- Apply a small amount of clean oil to the injector groove and the O-ring.
- Temporarily attach a new clip to the injector groove. NOTE: When the clip is attached correctly, the central area of the injector and the clip finger positions are aligned.
- Hold the injector firmly and push the clip into the injector until the clip stops sliding.
- Verify that the injector connector position is correct.
- Press the injector into the injector cup. Continue pressing until the clip contacts the lower surface of the injector cup.
- Verify that the injector and clip are correctly installed with the clip locked onto the injector cup notch.
