FUEL TANK REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. REMOVE FUEL TANK CAP ASSEMBLY

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


    1. B001VWF

      Remove the 5 bolts and No. 1 fuel tank protector sub-assembly.

  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    B001YRGE01
    Text in Illustration
    *1 Retainer *2 Pipe
    *3 Nylon Tube *4 Connector
    *5 O-Ring - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    B001XPG Pull Up - -

    1. Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the fuel tank main tube sub-assembly.

      Note


      • Check for foreign matter 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 forcefully bend or twist the nylon tube.

      • Check for foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

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

  5. DRAIN FUEL


    1. Connect the cable to the negative (-) battery terminal.

      Note

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

    2. Connect the intelligent tester to the DLC3.

    3. Turn the engine switch on (IG).

      Note

      Do not start the engine.

    4. Turn the intelligent tester on.

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

      CAUTION:


      • Do not smoke or be near an open flame when working on the fuel system.

      • Secure good ventilation.

      • Keep gasoline away from rubber or leather parts.

      Tech Tips

      If the fuel pump does not operate, remove the fuel tube joint clip and disconnect the fuel tank return tube, and drain fuel from the port shown in the illustration.

      B001WC6

    6. Disconnect the cable from the negative (-) battery terminal.

      Note

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

    7. B001VPA

      Disconnect the fuel pump and fuel sender gauge connector.

  6. PRECAUTION

    Note

    After turning the engine 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 REAR NO. 1 SEAT ASSEMBLY RH (for 60/40 Split Seat Type 40 Side)

    Click here

  9. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (for 60/40 Split Seat Type 60 Side)

    Click here

  10. REMOVE REAR NO. 2 SEAT ASSEMBLY


    1. for Face to Face Seat Type:

      Remove the rear No. 2 seat assembly Click here.

    2. except Face to Face Seat Type:

      Remove the rear No. 2 seat assembly Click here.

  11. REMOVE FRONT FLOOR CARPET ASSEMBLY


    1. Turn over the floor carpet.

      Tech Tips

      Fold back the floor carpet so that the air duct can be removed.

  12. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. B001WTX

      Remove the 2 screws and air duct.

    2. B001VV2

      Remove the rear floor No. 2 service hole cover.

  13. DISCONNECT NO. 2 FUEL TANK BREATHER HOSE


    1. B001XDU

      for G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Slide the clip and disconnect the No. 2 fuel tank breather hose from the pipe.

  14. DISCONNECT FUEL TANK RETURN TUBE

    B001XT4E01
    Text in Illustration
    *1 Retainer *2 Pipe
    *3 Nylon Tube *4 Connector
    *5 O-Ring - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    B001XPG Pull Up - -

    1. Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the fuel tank return tube.

      Note


      • Check for foreign matter 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 forcefully bend or twist the nylon tube.

      • Check for foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

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

  15. DISCONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY


    1. B001WPPE01
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      B001XPG Pull Up

      for G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Pull up the retainer and disconnect the No. 1 fuel emission tube sub-assembly.

        Note


        • Check for foreign matter 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 forcefully bend or twist the nylon tube.

        • Check for foreign matter on the pipe seal surface. Clean if necessary.

        • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

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

    2. B001YGNE01
      Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
      B001XPG Push
      B001WGT Pull Up

      except G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Pull the retainer up while pinching it on both sides by hand as shown in the illustration, and disconnect the No. 1 fuel emission tube sub-assembly.

        Note


        • Check for foreign matter 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 forcefully bend or twist the nylon tube.

        • Check for foreign matter on the pipe seal surface. Clean if necessary.

        • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

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

  16. DISCONNECT FUEL HOSE


    1. B001XGA

      for G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Slide the clip and disconnect the fuel hose from the pipe.

  17. DISCONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

    B001YZBE03
    Text in Illustration
    *1 Retainer *2 Connector
    *3 O-Ring *4 Pipe
    *5 Nylon Tube - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    B001XPG Pull Up - -

    1. Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the No. 2 fuel tank main tube sub-assembly.

      Note


      • Check for foreign matter 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 forcefully bend or twist the nylon tube.

      • Check for foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

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

  18. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE


    1. B001YWOE01
      Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
      B001XPG Pull Up

      except G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Pull up the retainer and disconnect the No. 2 fuel tank breather tube.

        Note


        • Check for foreign matter 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 forcefully bend or twist the nylon tube.

        • Check for foreign matter on the pipe seal surface. Clean if necessary.

        • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

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

  19. DISCONNECT FUEL TANK BREATHER TUBE


    1. B001YMZE01
      Text in Illustration
      *1 Retainer
      B001XPG Pull Up

      Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the fuel tank breather tube from the fuel tank to filler pipe sub-assembly.

      Note


      • Do not use any tools in this procedure.

      • 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.

  20. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B001VVH

      Loosen the hose clamp and disconnect the fuel tank to filler pipe hose from the fuel tank to filler pipe sub-assembly.

  21. REMOVE FUEL TANK SUB-ASSEMBLY


    1. Place an engine lifter under the fuel tank sub-assembly.

    2. B001Z78

      Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank band sub-assemblies.

    3. Slowly lower the engine lifter slightly.

  22. REMOVE FUEL HOSE


    1. B001XCW

      for G.C.C. Countries:

      Slide the clip and remove the fuel hose from the fuel suction tube sub-assembly.

  23. REMOVE FUEL TANK MAIN TUBE, FUEL TANK RETURN TUBE AND NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B001WKSE05
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Suction Plate Sub-assembly

      Remove the 3 tube joint clips and pull out the 3 fuel tube joints.

      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. B001YTGE02
      Text in Illustration
      *1 Fuel Tank Main Tube Sub-assembly
      *2 Fuel Tank Return Tube Sub-assembly
      *3 No. 2 Fuel Tank Main Tube Sub-assembly

      except G.C.C. Countries:


      1. Detach the clamp and remove the fuel tank main tube sub-assembly.

      2. Detach the clamp and remove the fuel tank return tube sub-assembly.

      3. Detach the 2 clamps and remove the No. 2 fuel tank main tube sub-assembly.

    3. B001W50E02
      Text in Illustration
      *1 Fuel Tank Main Tube Sub-assembly
      *2 Fuel Tank Return Tube Sub-assembly
      *3 No. 2 Fuel Tank Main Tube Sub-assembly

      for G.C.C. Countries:


      1. Detach the clamp and remove the fuel tank main tube sub-assembly.

      2. Detach the clamp and remove the fuel tank return tube sub-assembly.

      3. Detach the 2 clamps and remove the No. 2 fuel tank main tube sub-assembly.

  24. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

  25. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. B001VYZ

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

  26. REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    1. B001VKDE02
      Text in Illustration
      *a for G.C.C. Countries

      Remove the fuel tube clamp from the No. 1 fuel tank heat insulator.

    2. Using needle-nose pliers, remove the 4 clips shown in the illustration, and then remove the No. 1 fuel tank heat insulator.