FUEL TANK(for 3 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 FLOOR MAT SUPPORT PLATE

    Click here

  5. REMOVE REAR FLOOR SERVICE HOLE COVER

    Tech Tips

    Fold back the floor mat so that the rear floor service hole cover can be removed.


    1. B001GHR

      Remove the 3 screws and rear floor service hole cover.

    2. B001CQ6

      Disconnect the fuel sender gauge connector and fuel pump connector.

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


    1. B001HPG

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

  7. DRAIN FUEL


    1. B001EV6

      Remove the fuel tank drain plug and gasket and drain the fuel.

    2. Install a new gasket and the fuel tank drain plug.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  8. DISCONNECT FUEL MAIN TUBE


    1. B001F0M

      Disconnect the fuel main tube Click here.

  9. DISCONNECT FUEL HOSE


    1. B001FUA

      Disconnect the fuel evaporation hose and fuel hose.

  10. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B001FG3

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

  11. DISCONNECT FUEL TANK BREATHER HOSE


    1. B001G4U

      Disconnect the fuel tank breather hose from the filler pipe.

  12. REMOVE FUEL TANK SUB-ASSEMBLY


    1. Set an engine lifter underneath the fuel tank sub-assembly.

    2. B001GT4

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

    3. Remove the fuel tank sub-assembly.

  13. REMOVE FUEL SUCTION TUBE ASSEMBLY

    Click here

  14. REMOVE NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. B001GQ6

      Remove the 4 screws, detach the clamp and remove the No. 1 fuel evaporation tube sub-assembly.

    2. Remove the gasket from the No. 1 fuel evaporation tube sub-assembly.

  15. REMOVE FUEL CUT OFF VALVE ASSEMBLY


    1. Remove the fuel cut off valve assembly from the fuel tank sub-assembly.

  16. REMOVE FUEL SENDER GAUGE ASSEMBLY


    1. B001FUG

      Remove the 5 screws and fuel sender gauge assembly.

      Note

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

    2. Remove the gasket from the fuel sender gauge assembly.

  17. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. B001EK8

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

  18. REMOVE FUEL TANK BREATHER HOSE


    1. B001E75

      Remove the fuel tank breather hose from the fuel tank sub-assembly.

  19. REMOVE FUEL TANK FILLER PIPE LOWER SUB-ASSEMBLY


    1. B001GMN

      Remove the 8 screws and fuel tank filler pipe lower sub-assembly.

    2. Remove the gasket from the fuel tank filler pipe lower.

  20. REMOVE FUEL TUBE GROMMET


    1. B001G2F

      Detach the clamp and remove the fuel tube grommet.

  21. REMOVE NO. 1 FUEL TANK CUSHION


    1. B001DA7

      Remove the 2 No. 1 fuel tank cushions from the fuel tank sub-assembly.