FUEL TANK REMOVAL


  1. REMOVE REAR SEAT CUSHION ASSEMBLY


  2. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A0137CB

      Remove the rear floor service hole cover.

    2. Disconnect the fuel pump connector.

  3. DISCHARGE FUEL SYSTEM PRESSURE

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  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  5. DRAIN FUEL

  6. REMOVE FUEL PUMP GAUGE RETAINER


    1. Disconnect the fuel tank main tube sub-assembly.


      1. A0135YLE01

        Pinch the tube connector and then pull out the fuel tank main tube.

        Note


        • Check if there is any dirt around the connector before this operation and remove the dirt as necessary.

        • Be careful of mud because the quick connector has O-rings which seal the pipe and connector that can be contaminated.

        • Do not use any tool in this operation.

        • Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.

        • When the pipe and the connector are stuck, push and pull the connector to release. Pull out the connector carefully.

    2. Disconnect the fuel emission tube sub-assembly No.1.


      1. A0137LKE01

        Pinch the tube connector and then pull out the fuel emission tube.

        Note


        • Check if there is any dirt around the connector before this operation and remove the dirt as necessary.

        • Be careful of mud because the quick connector has O-ring which seals the pipe and connector that can be contaminated.

        • Do not use any tool in this operation.

        • Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.

        • When the pipe and the connector are stuck, push and pull the connector to release. Pull out the connector carefully.

    3. Remove the fuel pump gauge retainer.


      1. A01361JE01

        Using a socket wrench (6 mm), set SST to the fuel pump gauge retainer.

      2. Using SST, loosen the fuel pump gauge retainer.

        SST
        09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

        Note


        • Use SST. Do not use any other tools such as a screwdriver.

        • As the fuel pipes are located on the track of the SST, the SST should be reset a few times to prevent it from making contact with the pipes when removing the fuel pump gauge retainer.

        Tech Tips

        Fit the rib on the fuel pump gauge retainer into the cutout of the SST.

  7. REMOVE FUEL PUMP ASSEMBLY


    1. A0138KH

      Pull out the fuel pump assembly.

      Note

      The arm of the sender gauge should not be bent.

    2. Remove the gasket from the fuel tank.

  8. REMOVE EXHAUST PIPE ASSEMBLY FRONT


    1. Remove the bolt and clamp.

    2. Remove the 2 bolts, 2 compression springs and exhaust pipe gasket.

    3. Remove the exhaust pipe No.4 support and exhaust front pipe assembly.

      A0135VGE02

  9. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0138SQE01

      Disconnect the fuel tank main tube.


      1. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.

      2. Pull out the fuel tank main tube.

        Note


        • Check if there is any dirt or other foreign objects around the connector before this operation and clean the connector as necessary.

        • Be careful of mud because the quick connector has O-rings which seal the pipe and connector that can be contaminated.

        • Do not use any tools in this operation.

        • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.

        • When the pipe and connector stuck, push and pull the connector to release and pull the connector out carefully.

  10. DISCONNECT FUEL EMISSION TUBE SUB-ASSEMBLY NO.1


    1. A0136G1E01

      Disconnect the fuel emission tube.


      1. Pinch the tube connector and then pull out the fuel emission tube.

        Note


        • Check if there is any dirt or other foreign objects around the connector before this operation and clean the connector as necessary.

        • Be careful of mud because the quick connector has O-ring which seals the pipe and connector that can be contaminated.

        • Do not use any tools in this operation.

        • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.

        • When the pipe and connector stuck, push and pull the connector to release and pull the connector out carefully.

  11. SEPARATE FUEL TANK FILLER PIPE SUB-ASSEMBLY


    1. A0137U6

      Remove the bolt and separate the fuel tank filler pipe.

  12. REMOVE FUEL TANK ASSEMBLY


    1. A0138GSE01

      Remove the bolt and separate the parking brake cable No.2.

    2. Remove the bolt and separate the parking brake cable No.3.

    3. Place a transmission jack under the fuel tank.

    4. Remove the 4 bolts and fuel tank.

  13. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01360FE01

      Disengage the 4 claws on the fuel tank and remove the fuel tank main tube and fuel emission tube.

  14. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A01390K

      Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.

  15. REMOVE FUEL TANK PROTECTOR LOWER CENTER


    1. A01361D

      Remove the 3 screws and fuel tank protector lower center.