FUEL TANK REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge the fuel system pressure Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  3. REMOVE REAR SEAT ASSEMBLY LH


    1. for 60/40 Split Double-folding Seat Type LH Side:

      Remove the rear seat assembly LH Click here.

    2. for 60/40 Split Slide Walk-in Seat Type LH Side:

      Remove the rear seat assembly LH Click here.

  4. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. B001CK2

      Remove the 3 screws and rear floor service hole cover.

    2. B001F8PE01
      Text in Illustration
      *A for Single Tank Type
      *B for Double Tank Type

      Disconnect the fuel pump and sender gauge connector.

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


    1. B001HKN

      Remove the 6 bolts and No. 1 fuel tank protector.

    2. B001E80

      for Half Cover Type:

      Remove the 4 bolts and No. 1 fuel tank protector.

  6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B001F4S

      Disconnect the fuel tank main tube Click here.

  7. DRAIN FUEL


    1. Connect the intelligent tester to the DLC3.

    2. Turn the engine switch on (IG).

      Note

      Do not start the engine.

    3. Turn the intelligent tester 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.

  8. DISCONNECT FUEL RETURN TUBE SUB-ASSEMBLY


    1. B001FDG

      Disconnect the fuel return tube Click here.

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


    1. B001I9W

      Disconnect the fuel cut off tube Click here.

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


    1. B001CHA

      Disconnect the fuel cut off tube Click here.

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


    1. B001GFR

      Disconnect the fuel tank breather tube Click here.

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


    1. B001CPP

      Disconnect the fuel tank breather tube Click here.

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


    1. B001EHF

      Disconnect the No. 2 fuel main tube Click here.

  14. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B001DLU

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

  15. REMOVE FUEL TANK SUB-ASSEMBLY


    1. Place a transmission jack under the fuel tank.

    2. B001HC1

      Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.

    3. Slowly lower the transmission jack slightly.

  16. 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.

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


    1. B001GOUE01
      Text in Illustration
      *1 Fuel Tube
      *2 Fuel Tube Joint
      *3 Fuel Tube Joint Clip
      *4 O-Ring

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

      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 and fuel return tube from the fuel tank.

  18. 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. B001D3EE01
      Text in Illustration
      *1 Fuel Tube
      *2 Fuel Tube Joint
      *3 Fuel Tube Joint Clip
      *4 O-Ring

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

      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.

    3. Remove the fuel tank main tube and fuel return tube from the fuel tank.

  19. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

  20. REMOVE NO. 3 FUEL TANK PROTECTOR


    1. B001HXR

      Remove the 2 bolts.

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

  21. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. B001HMY

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