FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE REAR BENCH TYPE SEAT CUSHION ASSEMBLY (for Sedan)

    Click here

  2. REMOVE REAR BENCH TYPE SEAT CUSHION ASSEMBLY (for Wagon)

    Click here

  3. REMOVE NO. 1 QUARTER WHEEL HOUSE GUSSET SUB-ASSEMBLY

    Click here

  4. REMOVE REAR FLOOR SERVICE HOLE COVER

    Click here

  5. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge fuel system pressure Click here.

  6. PRECAUTION

    Note

    After turning the ignition 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.

  7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  8. REMOVE FUEL TANK CAP ASSEMBLY

  9. DRAIN FUEL

    Note

    These procedures should be performed with the fuel tank less than 1/4 full Click here.

  10. REMOVE TAILPIPE ASSEMBLY

    Click here

  11. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A0057VP

      Remove the 3 bolts and No. 1 fuel tank protector.

  12. DISCONNECT PARKING BRAKE CABLE


    1. A0054SB

      Remove the 2 nuts and 2 bolts, and disconnect the parking brake cable.

  13. DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A00592SE02
      Text in Illustration
      *1 O-Ring
      *2 Fuel Pipe
      *3 Retainer
      *4 Nylon Tube

      Pinch the projections of the retainer to detach the lock claws and pull off the tube as shown in the illustration.

      Note


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

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

      • Do not use any tools for this work.

      • Do not bend, kink or twist the nylon tube by force.

      • After disconnecting the tube, cover the connector with a plastic bag.

      • If the connector and pipe are stuck, pinch the tube between your fingers, turn the tube carefully to release it, and then disconnect the tube.

  14. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0055ROE01
      Text in Illustration
      *1 O-Ring
      *2 Fuel Pipe
      *3 Retainer
      *4 Nylon Tube

      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.

  15. DISCONNECT FUEL HOSE


    1. A0058T5

      Disconnect the fuel tank to filler pipe hose, fuel tank vent hose and No. 1 charcoal canister outlet hose.

  16. REMOVE FUEL TANK ASSEMBLY


    1. Set a transmission jack underneath the fuel tank.

    2. A0052TJ

      Remove the 4 bolts and 2 fuel tank bands.

    3. Slightly lower the transmission jack to remove the fuel tank from the vehicle body.

      Note

      Be careful not to cut the wiring.