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

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

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


  4. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type)

    Click here

  5. REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    A01GWKI

  6. REMOVE DECK BOARD ASSEMBLY (w/o Spare Tire)

    A01GZ3P

  7. REMOVE DECK TRIM SIDE BOARD LH (w/o Spare Tire)


    1. A01GXQQ

      Detach the 2 clips and remove the deck trim side board LH.

  8. REMOVE BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02
      Text in Illustration
      *A for Standard
      *B for Ottoman
      *1 Fastening Tape

      Detach the clip, fastening tape and remove the battery service hole cover LH.

  9. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

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

  10. REMOVE SERVICE PLUG GRIP

    Click here

  11. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. A01GWRK

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

  12. REMOVE FUEL TANK VENT TUBE SET PLATE


    1. A01H23LE01

      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.

    2. A01H1B2

      Remove the 8 bolts and No. 2 fuel tank protector and fuel tank vent tube set plate.

  13. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. A01H0EM

      Disconnect the fuel hose.

    2. 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 with pump and gauge tube.

    3. Remove the gasket.

  14. DRAIN FUEL

  15. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A01GW94

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

  16. REMOVE FUEL SENDER GAUGE ASSEMBLY


    1. A01H0IF

      Remove the 5 screws and fuel sender gauge assembly.

    2. Remove the gasket.

  17. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  18. REMOVE FUEL TANK FILLER PIPE PROTECTOR


    1. A01GWTT

      Remove the 2 clips, 2 nuts and protector.

  19. REMOVE FUEL TANK PROTECTOR BRACKET SIDE


    1. A01GWRZ

      Remove the 2 bolts and protector bracket.

  20. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01GYNEE01

      Disconnect the fuel tank main tube RH.

      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. A01H08KE01

      Disconnect the fuel tank main tube LH.

      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.

  21. DISCONNECT FUEL TANK RETURN VENT TUBE


    1. A01H1IGE01

      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 return vent 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 vent tube.

  22. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY


    1. A01H27AE01

      Disconnect the canister 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 canister 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 canister tube.

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


    1. A01GWJB

      Loosen the clamp and disconnect the breather tube.

  24. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A01H0A2

      Loosen the clamp and disconnect the filler pipe hose.

  25. REMOVE FUEL TANK ASSEMBLY


    1. A01GZ48

      Place a engine lifter under the fuel tank.

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

    3. 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 to canister tube sub-assembly.

      Tech Tips

      Lower the engine lifter slowly.

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


    1. A01H1EJ

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

  27. REMOVE FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY


    1. A01GYK2E01

      Disconnect the fuel tank to canister tube sub-assembly.


      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 canister 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 canister tube.

  28. REMOVE FUEL TANK RETURN VENT TUBE


    1. A01GY5N

      Remove the return vent tube from the fuel tank.

  29. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    A01GWXI

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

    2. Remove the fuel tube 6 clamps.

  30. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. Remove the fuel tank protector from the fuel tank.