FUEL TANK REMOVAL


  1. PRECAUTION

    CAUTION:


    • Do not smoke or be near an open flame when working on the fuel system.

    • Keep gasoline away from rubber or leather parts.

    • Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. REMOVE COWL TOP VENTILATOR LOUVER


    1. A01GM4S

      for LHD:

      Remove the 6 clips and cowl top ventilator louver RH.

    2. A01GI9P

      for RHD:

      Remove the 6 clips and cowl top ventilator louver LH.

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  5. REMOVE REAR NO.1 AND NO. 2 SEAT ADJUSTER ASSEMBLY


  6. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Type)

    Click here

  7. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER

    A01GLUC

    1. Remove the service hole cover and disconnect the connector from the fuel suction with pump and gauge tube.

  8. REMOVE FUEL TANK MAIN AND RETURN TUBE

    A01GK71E01

    1. Disconnect the fuel tank main tube and fuel tank return vent tube.


      1. Remove the 2 tube joint clips and disconnect the 2 fuel tubes.

        Note


        • Remove any dirt and foreign matter on the fuel tube joint before performing this work.

        • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.

        • Perform this work by hand. Do not use any tools.

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

        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.

  9. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A01GK8R

      Remove the service hole cover and disconnect the fuel sender gauge connector.

  10. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  11. REMOVE FUEL TANK FILLER PIPE PROTECTOR


    1. A01GL3U

      Remove the 2 nuts.

    2. Detach the 2 clips and protector.

  12. REMOVE FUEL TANK PROTECTOR SIDE BRACKET


    1. A01GIQN

      Remove the 2 bolts and protector bracket.

  13. REMOVE FUEL TANK ASSEMBLY


    1. A01GMINE01

      Disconnect the fuel tank main tube.

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

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

      • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.

    2. A01GMINE01

      Disconnect the fuel tank return vent tube.

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

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

      • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel return tube.

      • If the pipe and connector are stuck together, pinch the vent tube between your fingers and turn it carefully to free it. Then disconnect the fuel return tube.

    3. A01GKNC

      Loosen the clamp and disconnect the filler pipe hose.

    4. A01GK0N

      Place a engine lifter under the fuel tank.

    5. Remove the 4 bolts and 2 fuel tank bands.

    6. Lower the engine lifter so that the fuel tank breather tube can be disconnected.

      Note

      Make sure that no load is applied to the fuel filler pipe.

      Tech Tips

      Lower the engine lifter slowly.

    7. A01GM8O

      Disconnect the No. 1 fuel tank breather tube.

    8. A01GJKRE01

      Disconnect the fuel tank to canister tube.


      1. Pinch the retainer and then raise it.

        Note


        • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.

        • Do not use any tools to separate the pipe and connector.

        • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the vent hose contains the O-rings that seal the plug.

        • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

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

        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the vent hose.

        • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.

    9. Lower the engine lifter to remove the fuel tank from the vehicle.

      Note


      • Do not allow the fuel tank to contact the vehicle, especially the differential.

      • Make sure that the fuel tank is free from the fuel tank vent hose sub-assembly.

      Tech Tips

      Lower the engine lifter slowly.

  14. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. A01GIMC

      Remove the 8 bolts and, lower fuel tank protector and fuel vent tube set plate.

    2. A01GMKI

      Disconnect the fuel hose.

    3. Remove the fuel suction with pump and gauge tube from the fuel tank.

      Note


      • Make sure that the sender gauge arm does not bend.

      • Do not damage the fuel suction tube with pump and gauge tube.

    4. Remove the gasket.

  15. REMOVE FUEL SENDER GAUGE ASSEMBLY


    1. A01GHMO

      Remove the 5 screws and fuel sender gauge.

    2. Remove the gasket.

  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    A01GI7Q

    1. Remove the 6 clamps and fuel tank main tube from the fuel tank.

    2. A01GK4R

      Remove the fuel hose clamp.

  17. REMOVE NO. 2 FUEL TANK PROTECTOR

    A01GJI3

    1. Remove the bolt and clip and No. 2 fuel tank protector from the fuel tank.

    2. Remove the clamp from the fuel tank.

  18. REMOVE FUEL TANK CUSHION


    1. A01GING

      Remove the 6 tank cushions.

    2. A01GHXY

      Remove the tank protector and 5 tank cushions.