FUEL TANK REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge fuel system pressure Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE REAR SEAT CUSHION ASSEMBLY


    1. A0160U2E01

      Disengage the 2 front hooks of the rear seat cushion assembly from the vehicle body.

      Note

      Follow the instructions below carefully as the cushion frame deforms easily.


      1. Choose a hook to detach first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to detach the hook.

      2. Repeat for the other hook.

    2. Disengage the 2 rear hooks of the seat cushion from the child restraint seat anchor bracket.

    3. Remove the rear seat cushion assembly.

  4. REMOVE NO. 3 ROOM PARTITION PAD


    1. A015ZGAE01

      Remove the clip and No.3 room partition pad.

  5. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER


    1. A016306

      Remove the No. 2 rear floor service hole cover and disconnect the fuel suction tube connector.

  6. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. A015ZOX

      Disconnect the connector from the fuel suction with pump and gauge tube assembly.

    2. A0161RFE01

      Disconnect fuel pump tubes.

      Note

      Before beginning this procedure, check for foreign matter on the joint clips. Clean if necessary.


      1. Remove the 2 tube joint clips, fuel tank main tube and fuel tank return vent tube.

        Note


        • Keep the O-rings free of foreign matter, as it becomes contaminated easily.

        • Do not use any tools in this procedure.

        • Do not forcefully bend or twist the tube.

        • Put the tube in a plastic bag to prevent damage and contamination.

        • If the fuel suction plate and tube are stuck together, pinch the tube and turn it carefully to disconnect it.

        • Be careful not to damage any clips. If a clip is damaged, replace it.

    3. A01628S

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

      Tech Tips

      While holding the fuel suction tube by hand, remove the fuel tank vent tube set plate.

    4. A0162G3

      Disconnect the clip and fuel tube.

    5. Remove the fuel suction with pump and gauge tube assembly and fuel suction tube set gasket from the fuel tank.

      Note


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

      • Do not damage the fuel tube.

  7. DRAIN FUEL

  8. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A016254

      Remove the rear floor service hole cover.

  9. REMOVE FUEL SENDER GAUGE


    1. A015ZOG

      Disconnect the fuel sender gauge connector.

    2. A015YWB

      Remove the 5 bolts and fuel sender gauge from the fuel tank.

      Note

      Be careful not to bend the arm of the fuel sender gauge.

  10. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR


    1. A0163AZ

      Remove the 2 nuts and No. 2 differential support protector.

  11. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR

    Tech Tips

    Use the same procedure as for the No. 2 differential support protector.

  12. REMOVE NO. 2 FLOOR UNDER COVER

  13. REMOVE NO. 1 FLOOR UNDER COVER

  14. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Tech Tips

    Click here.

  15. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Tech Tips

    Click here.

  16. REMOVE REAR SUSPENSION REAR LOWER MEMBER BRACE LH


    1. A015ZSS

      Remove the 4 bolts and rear suspension member brace LH.

  17. REMOVE REAR SUSPENSION REAR LOWER MEMBER BRACE RH

    Tech Tips

    Perform the same procedure as the LH side.

  18. DISCONNECT PARKING BRAKE CABLE ASSEMBLY


    1. A0160G8

      Remove the 2 parking brake cable assemblies from the 4 clamps.

    2. Remove the 4 bolts and disconnect the 2 parking brake cable assemblies.

    3. A0160ZW

      Remove the bolt, loosen the grommet then remove No.3 fuel tank protector.

    4. Remove the bolt, loosen the grommet then remove No.4 fuel tank protector.

  19. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A015ZVYE01

      Disconnect the fuel tank main tube (LH side).

      Note


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

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

      • 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 after disconnecting the fuel pump tube.

      • If the fuel tube connector and pipe are stuck, push and pull on them to release them.

    2. A0163HBE01

      Disconnect the fuel tank return vent tube.

      Note


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

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

      • 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 after disconnecting the fuel pump tube.

      • If the fuel tube connector and pipe are stuck, push and pull on them to release them.

    3. A015ZETE05

      Disconnect the fuel tank main tube (RH side).

      Note


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

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

      • 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 after disconnecting the fuel pump tube.

      • If the fuel tube connector and pipe are stuck, push and pull on them to release them.

  20. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A015YHU

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

  21. DISCONNECT FUEL TANK VENT HOSE


    1. A0161XF

      Remove the clamp and disconnect the fuel tank vent hose.

  22. REMOVE FUEL TANK ASSEMBLY


    1. A0161EM

      Place a engine lifter under the fuel tank assembly.

    2. Remove the 4 bolts and fuel tank bands.

    3. A0160QQ

      Slightly lower the transmission jack.

    4. Disconnect the No. 1 fuel tank breather tube sub-assembly and remove the fuel tank assembly.

      Note


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

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

      • 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 after disconnecting the fuel pump tube.

      • If the fuel tube connector and pipe are stuck, push and pull on them to release them.

  23. REMOVE NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY


    1. A0162GS

      Remove the 4 screws, No. 1 fuel tank breather tube sub-assembly and gasket.

  24. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A015YOV

      Disconnect the clamp and remove the fuel tank main tube and fuel tank return vent tube.

    2. A0160NH

      Disconnect the 2 clamps and remove the edge protector.

    3. A015Z1OE01

      Remove the 2 tank bracket retainer sub-assemblies.

  25. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A016109

      Loosen the hose clamp bolt and remove the fuel tank to filler pipe hose from the fuel tank assembly.

  26. REMOVE FUEL TANK VENT HOSE


    1. A015ZXE

      Remove the clip and fuel tank vent hose.

  27. REMOVE FUEL TANK CUSHION


    1. A015YT7

      Remove the 11 fuel tank cushions shown in the illustration.

  28. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A015YNP

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