Fuel Tank Replacement (1.6L LLU)
Special Tools
For equivalent regional tools, refer to
Special Tools .
Removal Procedure
6. |
Disconnect the fuel tank
wiring harness inline connector (1). |
|
Warning:
Do not breathe the air through the EVAP component
tubes or hoses. The fuel vapors inside the EVAP components may
cause personal injury. |
7. |
Loosen and remove the clamp
(2). |
8. |
Remove the fuel tank filler
hose (3) from the fuel tank filler pipe (1). |
10. |
Disconnect the fuel tank
return pipe connector (1) from fuel return pipe (3). |
11. |
Disconnect the fuel tank feed
pipe connector (6) from fuel feed pipe (5). |
13. |
Install the EN-807
plugs and the EN-6015 plugs into the fuel
pipes. |
14. |
Disconnect the fuel tank
filler vent pipe connector (6). |
15. |
Install the EN-6015
plug into the fuel tank filler vent pipe. |
|
Warning:
To help avoid personal injury, always use jack
stands when you are working on or under any vehicle that is
supported only by a jack. |
|
Caution: When you are jacking or lifting a vehicle at the frame
side rails or other prescribed lift points, be certain that the
lift pads do not contact the catalytic converter, the brake pipes
or the fuel lines. If such contact occurs, vehicle damage or
unsatisfactory vehicle performance may result. |
16. |
Place a suitable adjustable
jack under the fuel tank. |
17. |
Remove the 2 fuel tank strap
bolts (4). |
18. |
Remove the 2 fuel tank straps
(5). |
|
Note: A second
technician is required.
|
19. |
Remove the fuel tank.
|
Disassemble Procedure
|
Warning:
Always wear safety goggles when working with fuel
in order to protect the eyes from fuel splash. |
2. |
Disconnect the fuel tank vent
pipe (2). |
3. |
Disconnect the evaporative
emission canister wiring harness plug. |
4. |
Disconnect the evaporative
emission canister purge pipe (4). |
5. |
Remove the evaporative
emission canister (1) from the evaporative emission canister
bracket (3). |
6. |
Push the fuel tank upper
baffle plate (2) down until the clip (1) lock into the lower baffle
plate. |
7. |
Remove the 2 fuel tank baffles
(3) from the fuel tank baffle holder (4) through the fuel tank fuel
pump module opening as shown in the sectional view. |
Assemble Procedure
1. |
Install the 2 fuel tank
baffles (3) to the fuel tank baffle holder (4) through the fuel
tank fuel pump module opening as shown in the sectional
view. |
2. |
Unclip the fuel tank upper
baffle plate (1) from the fuel tank lower baffle plate.
|
3. |
Install the evaporative
emission canister (1) to the evaporative emission canister bracket
(3). |
4. |
Connect the evaporative
emission canister purge pipe (4). |
5. |
Connect the evaporative
emission canister wiring harness plug. |
6. |
Connect the fuel tank vent
pipe (2). |
Installation Procedure
|
Note: Two technicians
are required.
|
1. |
Install the fuel tank.
|
2. |
Install the 2 fuel tank straps
(5). |
3. |
Install the 2 fuel tank strap
bolts (4). |
4. |
Remove the EN-6015
plug from the fuel tank filler vent pipe. |
5. |
Connect the fuel tank filler
vent pipe connector (6). |
6. |
Remove the EN-807
plugs and the EN-6015 plugs from the fuel
pipes. |
8. |
Connect the fuel tank return
pipe connector (1) to the fuel return pipe (3). |
9. |
Connect the fuel tank feed
pipe connector (6) to the fuel feed pipe (5). |
10. |
Install the clamp (2) to the
fuel tank filler hose (3). |
11. |
Install the fuel tank filler
hose (3) to the fuel tank filler pipe (1). |
12. |
Tighten the clamp (2).
|
13. |
Connect the fuel tank wiring
harness inline connector (1). |
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