FUEL SUB TANK REMOVAL

PROCEDURE


  1. 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.

  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.


    1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

  3. REMOVE SPARE TIRE

  4. REMOVE TAILPIPE ASSEMBLY

    Click here

  5. REMOVE SPARE WHEEL CARRIER CROSSMEMBER AND SPARE WHEEL CARRIER BRACKET


    1. Remove the bolt labeled A, and then loosen the 4 bolts labeled B.

      B001Z1OE01

    2. Slightly raise the spare wheel carrier crossmember, and then remove the 6 bolts labeled C, spare wheel carrier crossmember and 2 brackets.

  6. REMOVE NO. 1 SPARE WHEEL STOPPER


    1. B001WCF

      Remove the 2 bolts and spare wheel stopper.

  7. REMOVE FUEL TANK CAP ASSEMBLY

  8. DISCONNECT FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY


    1. B001YK4

      Disconnect the 2 fuel tank evaporation vent tubes.

  9. DISCONNECT FUEL HOSE


    1. B001XOH

      Disconnect the 3 fuel hoses.

  10. DISCONNECT FUEL TANK BREATHER HOSE


    1. B001ZXH

      Disconnect the breather hose from the filler pipe.

  11. DISCONNECT NO. 3 FUEL HOSE


    1. B001YDA

      Disconnect the fuel hose from the filler pipe.

  12. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B001WMQ

      Disconnect the hose from the filler pipe.

  13. REMOVE FUEL SUB TANK SUB-ASSEMBLY


    1. Disconnect the floor No. 3 wire connector.

    2. Using a clip remover, detach the 3 wire harness clamps.

    3. Place a transmission jack under the fuel sub tank.

    4. B001X78

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

    5. Lower the transmission jack to remove the fuel sub tank from the vehicle.

      Note

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

      Tech Tips

      Lower the transmission jack slowly.

  14. REMOVE FLOOR NO. 3 WIRE


    1. B001XTA

      Disconnect the sender gauge connector.

    2. Using a clip remover, detach the wire harness clamp.

  15. REMOVE FUEL SENDER GAUGE ASSEMBLY


    1. B001WXQ

      Remove the 5 screws and sender gauge.

      Note

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

    2. Remove the gasket from the sender gauge.

  16. REMOVE FUEL HOSE


    1. B001ZNS

      Remove the 3 fuel hoses.

  17. REMOVE FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY


    1. B001Z4S

      Remove the 2 fuel tank evaporation vent tubes.

  18. REMOVE FUEL AND EVAPORATION VENT TUBE SUB-ASSEMBLY


    1. B001YXR

      Remove the 6 bolts and fuel and evaporation vent tube.

    2. Remove the gasket from the fuel and evaporation vent tube.

  19. REMOVE FUEL TANK BREATHER HOSE


    1. B001ZX8

      Remove the breather hose from the fuel sub tank.

  20. REMOVE NO. 3 FUEL HOSE


    1. B001YJR

      Remove the fuel hose from the fuel sub tank.

  21. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. B001ZWE

      Remove the hose from the fuel sub tank.