Fuel tank ASSY (FA20)
Components Removal / installation
FUEL
FUEL TANK ASSY (FA20)
EXPLODED VIEW
REMOVAL
1. Fuel spill prevention procedure (Refer to 
)
)2. Draining of fuel (Refer to )
)3. Disconnection of the battery ground terminal (Refer to )
)4. Removal of separate type rear seat cushion ASSY RH (Refer to )
)5. Removal of separate type rear seat cushion ASSY LH (Refer to )
)
6. Rear floor service hole cover removal
(1) Push in the grommet to remove the grommet from the rear floor service hole cover.
(2) Remove the butyl tape and remove the rear floor service hole cover.
(3) Disconnect the fuel sub sender gauge connector.
7. Rear floor service hole cover NO.2 removal
(1) Push in the grommet to remove the grommet from the rear floor service hole cover NO.2.
(2) Remove the butyl tape and remove the rear floor service hole cover NO.2.
(3) Disconnect the fuel pump connector.
(4) Disconnect the fuel delivery tube. (Refer to )
)CAUTION:
Be careful not to spill fuel.
8. Removal of rear suspension member SUB-ASSY
(Refer to )
)
9. Removal of the fuel tank protector NO.1
(1) Remove the 2 nuts and the 2 clips and remove the fuel tank protector NO.1.
10. Removal of the fuel tank protector NO.2
(1) Remove the 2 nuts and the 2 clips and remove the fuel tank protector NO.2.
11. Parking brake cable ASSY NO.3 removal (Refer to )
)12. Parking brake cable ASSY NO.2 removal (Refer to )
)
13. Disconnecting the fuel tank to filler pipe hose
(1) Loosen the hose clamp, and disconnect the fuel tank to filler pipe hose.
14. Disconnecting the evaporation hose
(1) Disconnect the evaporation hose from the 2-way valve.
15. Disconnecting the air vent hose
(1) Disconnect the air vent hose.
16. Fuel tank ASSY removal
CAUTION:
·Two persons are required to perform this procedure.
·The fuel may remain in the fuel tank and this may cause the left and right sides to be unbalanced. Be careful not to let the fuel tank ASSY fall off.
·The fuel may remain in the fuel tank and this may cause the left and right sides to be unbalanced. Be careful not to let the fuel tank ASSY fall off.
(1) Hold the fuel tank with the transmission jack.
(2) Remove the four bolts and remove the fuel tank band NO.1.
(3) Lower the transmission jack to remove the fuel tank ASSY.
INSTALLATION
1. Fuel tank ASSY installation
(1) Check the fuel tank cover.
NOTE:
As the fuel tank cover is used as a guide when installing the fuel tank ASSY, check for deformation, cracks, and other damages. If there is any problem, replace it with a new part
(2) Hold the fuel tank ASSY with the transmission jack.
(3) Temporarily install the fuel tank ASSY to the body with the two fuel tank bands NO.1 and four bolts.
(4) Adjust the fuel tank ASSY position so that the distance from the arrest hole of parking brake cable fixing bracket to the front edge of fuel tank cover is within the standard value.
Standard value
: 42 to 44 mm {1.654 to 1.732 in}
(5) Measure the distances from the left and right side of fuel tank ASSY to the body, respectively, and adjust the position of fuel tank ASSY so that the difference between the left and right values is within the standard value.
Standard value
: 2 mm {0.079 in} or less
(6) Tighten the four bolts in the order as shown in the figure and install the fuel tank band NO.1.
Standard value:
Standard value:
Tightening torque=33N·m
{
337kgf·cm}
{24.3ft·lbf}
2. Connecting the air vent hose
(1) Connect the air vent hose to the filler pipe.
3. Connecting the evaporation hose
(1) Connect the evaporation hose to the 2-way valve.
4. Fuel tank to filler pipe, hose connection
(1) Connect the fuel tank to filler pipe hose with the hose clamp.
Standard value:
Standard value:
Tightening torque=2.0N·m
{
20kgf·cm}
{1.5ft·lbf}
5. Parking brake cable ASSY NO.3 installation (Refer to )
)6. Parking brake cable ASSY NO.2 installation (Refer to )
)7. Installation of the fuel tank protector NO.1
(1) Install the fuel tank protector NO.1 with 2 new nuts and 2 clips.
Standard value:
Standard value:
Tightening torque=9.0N·m
{
92kgf·cm}
{6.6ft·lbf}
8. Installation of the fuel tank protector NO.2
(1) Install the fuel tank protector NO.2 with 2 new nuts and 2 clips.
Standard value:
Standard value:
Tightening torque=9.0N·m
{
92kgf·cm}
{6.6ft·lbf}
9. Installation of rear suspension member SUB-ASSY
(Refer to )
)
10. Fuel sub sender gauge connector installation
(1) Connect the fuel sub sender gauge connector.
11. Fuel delivery tube installation
(1) Connect the fuel delivery tube. (Refer to )
)
12. Fuel pump connector installation
(1) Connect the fuel pump connector.
13. Fuel refill
14. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
15. Exhaust gas leakage check (Refer to )
)
16. Rear floor service hole cover installation
(1) Install the rear floor service hole cover using new butyl tape.
(2) Install the grommet to the rear floor service hole cover.
17. Rear floor service hole cover NO.2 installation
(1) Install the rear floor service hole cover NO.2 using new butyl tape.
(2) Install the grommet to the rear floor service hole cover NO.2.
18. Separate type rear seat cushion ASSY RH installation (Refer to )
)19. Separate type rear seat cushion ASSY LH installation (Refer to )
)