FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE REAR SEAT CUSHION ASSEMBLY


    1. for Sedan:

      Remove the rear seat cushion assembly Click here.

    2. for Wagon:

      Remove the rear seat cushion assembly Click here.

  2. REMOVE REAR FLOOR SERVICE HOLE COVER

    Click here

  3. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    Click here

  4. DISCONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY

    Click here

  5. REMOVE TANK SUCTION TUBE SUPPORT

    Click here

  6. REMOVE FUEL PUMP GAUGE RETAINER

    Click here

  7. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY

    Click here

  8. DRAIN FUEL

  9. REMOVE TAILPIPE ASSEMBLY

    Click here

  10. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A004R3U

      Remove the 3 bolts and protector.

  11. REMOVE REAR FLOOR SIDE MEMBER COVER RH


    1. A004RNO

      Remove the clip, 2 grommets and rear floor side member cover RH.

  12. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A004TWM

      Loosen the hose clamp bolt, and then disconnect the filler pipe hose from the fuel tank.

  13. REMOVE FUEL TANK ASSEMBLY


    1. A004NT1

      Loosen the hose clamp bolt, and then disconnect the breather hose.

    2. A004R7D

      Remove the 2 bolts and disconnect the parking brake cable.

    3. Disconnect the fuel tank return tube.


      1. Pinch the tabs of the retainer of the fuel tube connector to detach the lock claws and push the retainer down as shown in the illustration.

        A004RKOE01

      2. Pull the fuel tank return tube off of the pipe.

        Note


        • Remove any dirt or foreign objects on the fuel tube connector before starting this step.

        • Do not scratch or allow foreign matter to adhere to the parts when disconnecting the fuel tube connector as the fuel tube connector contains the O-ring that seals the pipe.

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

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

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

        • If the fuel tube connector and pipe are stuck, push and pull the connector to disconnect it.

    4. Disconnect the fuel tank main tube.


      1. Pinch the tabs of the retainer of the fuel tube connector to detach the lock claws and push the retainer down as shown in the illustration.

        A004PW6E01

      2. Pull the fuel tank main tube off of the pipe.

        Note


        • Remove any dirt or foreign objects on the fuel tube connector before starting this step.

        • Do not scratch or allow foreign matter to adhere to the parts when disconnecting the fuel tube connector as the fuel tube connector contains the O-ring that seals the pipe.

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

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

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

        • If the fuel tube connector and pipe are stuck, push and pull the connector to disconnect it.

    5. Using a transmission jack, support the fuel tank.

    6. A004NA0

      Remove the 4 bolts and 2 fuel tank bands.

    7. Lower the transmission jack to remove the fuel tank.

      Note


      • Do not drop the fuel tank.

      • When removing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

  14. REMOVE FUEL TANK CUSHION


    1. A004SEXE01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion

      Remove the No. 1 fuel tank cushion and 3 No. 2 fuel tank cushions.

  15. REMOVE FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A004OJK

      Detach the 2 clamps and remove the fuel tank return tube.

  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A004SK8

      Detach the 2 clamps and remove the fuel tank main tube.