Page 3169 of 5883

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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1. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap to release the pressure inside the fuel tank.
3. Remove rear seat cushion. Refer to SE-18, "
Removal and Installation".
4. Remove the fuel pump inspection hole cover.
5. Disconnect electrical connector.
6. Disconnect the quick connector.
Hold the sides of the connector, push in tabs and pull out the
tube.
If quick connector and tube on fuel pump assembly are stuck,
push and pull several times until they move. Disconnect them
by pulling.
CAUTION:
The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
Do not use any tools to remove the quick connector.
Keep resin tube away from heat. Be especially careful
when welding near the resin tube.
Prevent acid liquid such as battery electrolyte, from get-
ting on resin tube.
Do not bend or twist resin tube during installation and removal.
To keep the connecting portion clean, free of foreign
materials and to avoid damage, cover them completely
with plastic bags or something similar.
Do not insert plug to prevent damage to O-ring in quick
connector.
7. Using lock ring wrench, remove lock ring (2).
8. Remove fuel level sensor unit (1).
CAUTION:
Do not bend float arm during removal.
Do not allow foreign materials to fall into fuel tank. Use a
lint free cloth when handling components.
Avoid impacts such as dropping when handling compo-
nents.
INSPECTION AFTER REMOVAL
Make sure that the fuel level sensor unit, fuel filter and fuel pump is free from defects and foreign materials.
INSTALLATION
Installation is in the reverse order of removal.
SFE562A
PBIC0163E
E1BIA0033ZZ
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FL-10
< ON-VEHICLE REPAIR >
FUEL TANK
FUEL TANK
HR16DE, HR18DEINFOID:0000000001723029
Exploded ViewINFOID:0000000001723030
Removal and InstallationINFOID:0000000001723064
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-4, "
General Pre-
caution".
1. Remove fuel pump. Refer to FL-5, "
Removal and Installation".
2. Drain fuel from fuel tank if necessary. Refer to FL-5, "
Removal and Installation".
CAUTION:
Because fuel tank becomes unstable when installing/removing, fuel should be drained if the
level exceeds specification FL-5, "
Removal and Installation".
Situate vehicle on a flat and solid surface.
3. Remove muffler. Refer to EX-5, "
Removal and Installation" (HR16DE) or EX-10, "Removal and Installa-
tion" (MR20DE).EX-10, "Removal and Installation"
4. Remove fuel tank shield.
5. Remove rear seat bottom. Refer to SE-18, "
Removal and Installation".
1. Fuel filler cap 2. Grommet 3. Fuel filler tube
4. Cover 5. Clamp 6. Fuel filler hose
7. Hose clamp 8. Fuel tank band (RH) 9. Fuel tank band (LH)
10. Fuel tank shield 11. Fuel tank 12. Vent hose
JPBIA0298GB
Page 3171 of 5883
FUEL TANK
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6. Disconnect EVAP tube (2) at rear side of fuel tank.
Vent hose (1)
⇐ : Vehicle front
7. Remove fuel filler hose (3) at fuel filler tube side.
8. If necessary, remove mounting screw and quick connectors and
slide the EVAP canister rearward to remove it from the fuel tank.
9. Support center of fuel tank (1) with transmission jack (A).
10. Remove fuel tank straps (RH and LH).
11. Lower transmission jack carefully to remove fuel tank while sup-
porting it by hand.
CAUTION:
Fuel tank may be in an unstable position because of the
shape of fuel tank bottom. Be sure to support tank securely.
INSTALLATION
Note the following, and install in the reverse order of removal.
Fuel Filler Hose
Install fuel filler hose to fuel tank, paying attention to install
mark.Marking faces downward
JPBIA0456ZZ
MBIB9040E
PBIC3792E
MBIB9043E
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FL-12
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FUEL TANK
Install fuel filler hose (2) to fuel filler tube (1), paying attention to
install mark. Marking faces rightward.
Insert filler hose to the length below.
When installing clamp, do not allow clamp to contact the bulge
(bump) part of the tube.
Tighten the clamp of filler hose so that the remaining length of the
screw becomes the following.
EVAP Hose
1. Check connections for damage or foreign material.
2. Align the matching side connection part with the center of shaft,
and insert connector straight until it clicks.
3. After connecting, pull out quick connector and centralized under-
floor piping by hand. Make sure connections are secure.
Installation of Fuel Tank Mounting Strap
Install them in the proper position by referring to the identification stamp mark “R” and “L1” on the end.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch “ON” (without starting the engine), to check the connections for fuel leaks with the
electric fuel pump applying pressure to the fuel piping.
2. Start the engine and let it idle to check that there are no fuel leaks at the fuel system connections. : 35mm (1.38 in)
: 5 - 9mm (0.20 - 0.35 in)
MBIB9043E
PBIC1653E
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FUEL TANK
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K9KINFOID:0000000001723031
Exploded ViewINFOID:0000000001723037
Removal and InstallationINFOID:0000000001722981
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-4, "
General Pre-
caution".
1. Remove RH rear wheel.
2. Remove fuel level sensor unit. Refer to FL-8, "
Removal and Installation".
CAUTION:
If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes
unstable, causing a danger. Drain fuel further than that in step 1 of the referenced procedure
until tank can be held by hand even if the balance is lost..
3. Remove muffler. Refer to EX-14, "
Removal and Installation"
4. Remove vehicle side insulator on upper center muffler and main muffler..
5. Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable. .
1. Fuel filler tube protector 2. Fuel filler cap 3. Fuel filler cap protector
4. Fuel filler tube 5. Hose clamp 6. Fuel filler hose
7. Hose clamp 8. Fuel tank 9. Fuel tank mounting straps
10. Fuel tank shield 11. Vent hose
E1BIA0014GB
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FL-14
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FUEL TANK
6. Disconnect fuel filler hose on fuel tank side.
CAUTION:
If fuel tank bottom face is not level, and remaining fuel
level is high, tank position becomes unstable, causing a
danger. Drain fuel further than that in step 1 of the refer-
enced procedure until tank can be held by hand even if
the balance is lost..
7. Remove vent hose at RH rear wheelwell side.
8. Remove EVAP hose at front side of fuel tank.
Disconnect the quick connector using the following procedure.
- Pinch quick connector square-parts with your fingers, and pull out
the quick connector by hand.
- If quick connector and tube on vehicle are stuck, push and pull
several times until they move, and pull out..
CAUTION:
The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
Do not use any tools to remove the quick connector.
Keep resin tube away from heat. Be especially careful when
welding near the resin tube.
Prevent acid liquid such as battery electrolyte, from getting
on resin tube.
Do not bend or twist resin tube during installation and removal.
To keep the connecting portion clean, free of foreign materi-
als and to avoid damage, cover them completely with plastic
bags or something similar.
Do not insert plug to prevent damage to O-ring in quick con-
nector.
PBIC1505E
PBIC1507E
PBIC1509E
PBIC0163E
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FUEL TANK
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9. Support center of fuel tank (1) with transmission jack (A).
CAUTION:
Securely support the fuel tank with a suitable tool (B).
10. Remove fuel tank mounting straps.
11. Lower transmission jack carefully to remove fuel tank while sup-
porting it by hand. Perform the following works at the same time.
Pull out vent hose from through hole of vehicle.
Avoid interference with tank by pulling parking brake cable by
hand.
CAUTION:
Fuel tank may be in an unstable position because of the
shape of fuel tank bottom. Be sure to support tank securely.
INSTALLATION
Installation is in the reverse order of removal.
EVAP Hose
1. Check connections for damage or foreign material.
2. Align the mating side connection part with the center of shaft,
and insert connector straight until it clicks.
3. After connecting, pull out quick connector by hand. Make sure
connections are secure.
Installation of Vent Hose
Push vent hose into through hole of vehicle.
Insert vent hose into vent rubber hose, and secure it with clamp.
Installation of Fuel Tank Mounting Strap
Install them in the proper position by referring to the identification stamp mark “R” and “L1” on the end.
Fuel Filler Hose
Insert fuel filler hose to the length below.
When installing clamp, do not allow clamp to contact the bulge (bump) part of the tube.
Tighten the clamp of filler hose.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch “ON” (without starting the engine), to check the connections for fuel leaks with the
electric fuel pump applying pressure to the fuel piping.
2. Start the engine and let it idle to check that there are no fuel leaks at the fuel system connections.
PBIC3792E
PBIC1508E
: 35mm (1.38 in)
Filler hose clamp : 2.5 N·m (0.26 kg-m, 22 in-lb)
Page 3176 of 5883
FL-16
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and LimitINFOID:0000000001722982
FUEL TANK
Unit: (Imp gal)
Fuel tank capacity52.0 (11 1/2)
Fuel recommendation Refer to MA-19