FUEL TANK(w/o Canister Pump Module) REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the fuel tank assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedure Effect/Inoperative when not Performed Link
Disconnect cable from negative battery terminal Memorize steering angle neutral point Parking assist monitor system

Click here

LKA/LDA system

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Pre-crash safety system
Adaptive high beam system
Reset power trunk lid Power trunk lid system

Click here

CAUTION:


  • B002CR9

    Never perform work on fuel system components near any possible ignition sources.

  • Vaporized fuel could ignite, resulting in a serious accident.


  • B002EKE

    Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.

  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

    Click here

  3. DRAIN FUEL

  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B002CC3C01
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B002DP3 Push
      B002CU5 Pull out
      B002CVE Pull off

      Disconnect the fuel tank main tube sub-assembly on the LH side.

      Note

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

        • Do not forcibly bend, twist or turn the nylon tube.

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    2. B002DD2C01
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B002DP3 Push
      B002CU5 Pull out
      B002CVE Pull off

      Disconnect the fuel tank main tube sub-assembly on the RH.

      Note

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

        • Do not forcibly bend, twist or turn the nylon tube.

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  6. DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. B002DFSC01
      *a Retainer
      *b Fuel Tube Connector
      *c O-ring
      *d Fuel Pipe
      *e Claw
      B002DP3 Push
      B002CU5 Pull out
      B002CVE Pull off

      Disconnect the No. 1 fuel evaporation tube sub-assembly.

      Note

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the fuel pipe.

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  7. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B002CEH

      Loosen the clamp, then disconnect the fuel tank to filler pipe hose from the fuel tank assembly.

  8. DISCONNECT FUEL TANK BREATHER TUBE


    1. B002CSI

      Loosen the clamp and disconnect the fuel tank breather tube from the fuel tank breather tube connector.

    2. B002CAWC01
      *1 Breather Tube Clamp
      *2 No. 2 Evaporation Vent Tube Clamp

      Disengage the 2 clamps to disconnect the fuel tank breather tube from the breather tube clamp and No. 2 evaporation vent tube clamp.

  9. DISCONNECT CHARCOAL CANISTER OUTLET HOSE


    1. B002DRT

      Disconnect the charcoal canister outlet hose from the No. 6 fuel tank breather tube.

  10. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

    Click here

  11. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

    Click here

  12. REMOVE FUEL TANK ASSEMBLY


    1. B002E8UC01
      B002DP3 Bolt
      B002CU5 Nut

      Support the fuel tank assembly using an engine lifter.

      Tech Tips

      Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

    2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank band sub-assemblies.

    3. Lower the engine lifter to remove the fuel tank assembly.

      Note


      • Slowly operate the engine lifter to lower the fuel tank assembly.

      • Do not drop the fuel tank assembly.

      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

  13. REMOVE NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. B002D95

      Remove the No. 1 fuel evaporation tube sub-assembly from the fuel tank assembly.

  14. REMOVE CHARCOAL CANISTER OUTLET HOSE


    1. B002CIY

      Disengage the clamp to remove the charcoal canister outlet hose from the fuel tank assembly.

    2. B002E3M

      Disengage the clamp to remove the No. 4 fuel tube clamp from the fuel tank assembly.

  15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B002EKB

      Disengage the 2 clamps to remove the fuel tank main tube sub-assembly from the fuel tank assembly.

    2. B002D1QC01
      *1 No. 3 Fuel Tube Clamp
      *2 No. 5 Fuel Tube Clamp

      Disengage the 2 clamps to remove the No. 3 fuel tube clamp and No. 5 fuel tube clamp from the fuel tank assembly.

  16. REMOVE FUEL TANK CUSHION


    1. B002CH1

      Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly.

    2. B002E0TC04
      *1 Fuel Tank Bracket
      *2 Fuel Tank Cushion
      *3 Fuel Tank Cushion Set
      *a RH Side
      *b LH Side

      Remove the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set from the fuel tank assembly.

  17. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. B002DUCC03
      *1 No. 1 Fuel Tank Protector Sub-assembly
      *2 No. 2 Fuel Tank Protector
      *3 No. 3 Fuel Tank Protector

      Remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.

    2. Remove the No. 2 fuel tank protector and No. 3 fuel tank protector from the fuel tank assembly.