FUEL TANK REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE REAR SEAT CUSHION ASSEMBLY


  3. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A0138GQ

      Remove the rear floor service hole cover.

    2. Disconnect the connector.

  4. REMOVE FUEL PUMP GAUGE RETAINER


    1. A01366IE01

      Disconnect the fuel tank return tube sub-assembly.


      1. Pinch the tube connector and then pull out the fuel tank return tube.

        Note


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

        • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-rings may not seal properly.

        • Remove the quick connector by hand.

        • Do not damage the disconnected pipe and connector. Prevent intrusion of foreign objects by covering them with plastic bags.

        • If the pipe and the connector are stuck, try wiggling or pushing and pulling the connector to release it. Pull the connector off of the pipe carefully.

    2. A0137G0E01

      Disconnect the fuel tank main tube sub-assembly.


      1. 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.

        • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-rings may not seal properly.

        • Remove the quick connector by hand.

        • Do not damage the disconnected pipe and connector. Prevent intrusion of foreign objects by covering them with plastic bags.

        • If the pipe and the connector are stuck, try wiggling or pushing and pulling the connector to release it. Pull the connector off of the pipe carefully.

    3. A0136YDE01

      Remove the fuel pump gauge retainer.

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

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

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

      Note

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

      Tech Tips

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

  5. REMOVE FUEL SENDER GAUGE ASSEMBLY


    1. A0137P3

      Pull out the fuel sender gauge assembly.

      Note

      The sender gauge arm should not be bent.

    2. Remove the gasket from the fuel tank.

  6. DRAIN FUEL

  7. REMOVE EXHAUST FRONT PIPE ASSEMBLY


    1. Remove the bolt and clamp.

    2. Remove the exhaust front pipe stay nut and exhaust pipe support No.4.

    3. Remove the nut, clamp and the exhaust front pipe assembly.

      A0137Z8E02

  8. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0135VFE01

      Disconnect the fuel tank main tube sub-assembly.


      1. Pinch the tabs of the retainer to disengage 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.

        • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-rings may not seal properly.

        • Remove the quick connector by hand.

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

        • If the pipe and connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully.

  9. DISCONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A0137UVE01

      Disconnect the fuel tank return tube sub-assembly.


      1. Pinch the tube connector and then pull out the fuel tank return tube.

        Note


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

        • It is necessary to prevent mud or dirt from entering the quick connector. If mud enters the connector, the O-rings may not seal properly.

        • Remove the quick connector by hand.

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

        • If the pipe and connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully.

  10. SEPARATE FUEL TANK FILLER PIPE SUB-ASSEMBLY


    1. A0137U6

      Remove the bolt and separate the fuel tank filler pipe.

  11. 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.

  12. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01360FE02

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

  13. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A01390K

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

  14. REMOVE FUEL TANK PROTECTOR LOWER CENTER


    1. A01361D

      Remove the 3 screws and fuel tank protector lower center.