FUEL TANK(for 5 Door) REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. 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.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  4. REMOVE REAR SEAT ASSEMBLY LH


    • for 60/40 Split Double-folding Seat Type LH Side: Click here

    • for 60/40 Split Slide Walk-in Seat Type LH Side: Click here

  5. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. B001CK2

      Remove the 3 screws and rear floor service hole cover.

    2. B001EWXE01
      Text in Illustration
      *A for Single Tank Type
      *B for Double Tank Type

      Disconnect the fuel pump and sender gauge connector.

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


    1. B001HKN

      Remove the 6 bolts and No. 1 fuel tank protector sub-assembly.

  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B001F4S

      Disconnect the fuel tank main tube sub-assembly Click here.

  8. DRAIN FUEL


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON.

      Note

      Do not start the engine.

    3. Turn the GTS on.

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

    5. Operate the fuel pump and drain the fuel from the fuel tank main tube.

      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.

  9. DISCONNECT FUEL RETURN TUBE SUB-ASSEMBLY


    1. B001FDG

      Disconnect the fuel return tube sub-assembly Click here.

  10. DISCONNECT FUEL CUT OFF TUBE (for Single Tank Type)


    1. B001I9W

      Disconnect the fuel cut off tube Click here.

  11. DISCONNECT FUEL CUT OFF TUBE (for Double Tank Type)


    1. B001C9G

      Disconnect the fuel cut off tube Click here.

  12. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. B001GFR

      Disconnect the fuel tank breather tube sub-assembly Click here.

  13. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. B001F26

      Disconnect the fuel tank breather tube sub-assembly Click here.

  14. DISCONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. B001C8Y

      Disconnect the No. 2 fuel main tube sub-assembly Click here.

  15. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B001DLU

      Disconnect the fuel tank to filler pipe hose from the filler pipe.

  16. REMOVE FUEL TANK SUB-ASSEMBLY


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

    2. B001HC1

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

    3. Slowly lower the engine lifter slightly.

  17. REMOVE FUEL TANK CUSHION


    1. B001HUVE01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion
      *3 No. 3 Fuel Tank Cushion

      Remove the No. 1, No. 2 and No. 3 fuel tank cushions from the fuel tank.

  18. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. B001GOUE02
      Text in Illustration
      *a Fuel Tube
      *b Fuel Tube Joint
      *c Fuel Tube Joint Clip
      *d O-Ring

      Remove the 2 fuel tube joint clips and pull out the fuel tank main tube sub-assembly and fuel return tube sub-assembly.

      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. B001HS7

      Remove the fuel tank main tube sub-assembly and fuel return tube sub-assembly from the fuel tank sub-assembly.

  19. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY, FUEL RETURN TUBE SUB-ASSEMBLY AND NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. B001D3EE03
      Text in Illustration
      *a Fuel Tube
      *b Fuel Tube Joint
      *c Fuel Tube Joint Clip
      *d O-Ring

      Remove the 3 fuel tube joint clips and pull out the fuel tank main tube sub-assembly, fuel return tube sub-assembly and No. 2 fuel main tube sub-assembly.

      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. B001DRT

      Detach the clamp and remove the No. 2 fuel main tube sub-assembly from the fuel tank sub-assembly.

    3. Remove the fuel tank main tube sub-assembly and fuel return tube sub-assembly from the fuel tank sub-assembly.

  20. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

  21. REMOVE NO. 3 FUEL TANK PROTECTOR


    1. A01XI4K

      Remove the 2 bolts.

    2. Detach the 4 clamps and remove the No. 3 fuel tank protector.

  22. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. B001HMY

      Remove the fuel tank to filler pipe hose from the fuel tank sub-assembly.