FUEL TANK REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. REMOVE REAR SEAT ASSEMBLY

    Click here

  3. REMOVE FRONT FLOOR CARPET ASSEMBLY

    B00182Y

    1. Turn over the floor carpet.

      Tech Tips

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

  4. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. B0018LZ

      Remove the 2 screws and air duct.

    2. B0019W1

      Remove the rear floor No. 2 service hole cover.

  5. REMOVE FUEL TANK CAP ASSEMBLY

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


    1. B001AFE

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

  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. B001A7WE03
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Nylon Tube
      *d Connector
      *e O-Ring
      B0018FC Pull Up

      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.

  8. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)

    B0019XIE03
    Text in Illustration
    *a except G.C.C. Countries *b for G.C.C. Countries
    *c Retainer *d Pipe
    *e Nylon Tube *f Connector
    *g O-Ring - -
    B0018FC 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.

  9. 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 (See page ).

    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.

    6. Disconnect the cable from the 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.

    7. B00199GE03
      Text in Illustration
      *a for Single Tank Type
      *b for Double Tank Type

      Disconnect the fuel pump and fuel sender gauge connector.

  10. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. B001A6GE03
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Nylon Tube
      *d Connector
      *e O-Ring
      B0018FC Pull Up

      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.

  11. DISCONNECT NO. 2 FUEL TANK BREATHER HOSE (for Double Tank Type)


    1. B001A8C

      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.

  12. DISCONNECT FUEL TANK RETURN TUBE (for Single Tank Type)


    1. B001AC2E03
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Nylon Tube
      *d Connector
      *e O-Ring
      B0018FC Pull Up

      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.

  13. DISCONNECT FUEL TANK RETURN TUBE (for Double Tank Type)

    B00198RE03
    Text in Illustration
    *a except G.C.C. Countries *b for G.C.C. Countries
    *c Retainer *d Pipe
    *e Nylon Tube *f Connector
    *g O-Ring - -
    B0018FC 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.

  14. DISCONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. B001AO4E03
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Nylon Tube
      *d Connector
      *e O-Ring
      B0018FC 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. B00182ZE03
      Text in Illustration
      *a Retainer
      *b Connector
      *c O-Ring
      *d Pipe
      *e Nylon Tube
      B0018FC Push
      B00199O 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.

  15. DISCONNECT FUEL HOSE (for Double Tank Type)


    1. B001A4Q

      for G.C.C. Countries:


      1. Detach the fuel tube clamp.

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

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

    B0018Q9E05
    Text in Illustration
    *a except G.C.C. Countries *b for G.C.C. Countries
    *c Retainer *d Connector
    *e O-Ring *f Pipe
    *g Nylon Tube - -
    B0018FC 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.

  17. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. B0019IRE03
      Text in Illustration
      *a Retainer
      *b Connector
      *c O-Ring
      *d Pipe
      *e Nylon Tube
      B0018FC 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.

  18. DISCONNECT FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. B001B28E02
      Text in Illustration
      *a Retainer
      B0018FC 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.

  19. DISCONNECT FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. B0019HWE02
      Text in Illustration
      *a Retainer
      B0018FC 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 (for Single Tank Type)


    1. B00196N

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

  21. DISCONNECT FUEL TANK TO FILLER PIPE HOSE (for Double Tank Type)


    1. B001A4A

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

  22. REMOVE FUEL TANK SUB-ASSEMBLY


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

    2. B001AIF

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

    3. Slowly lower the engine lifter slightly.

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


    1. B001AZXE05
      Text in Illustration
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-Ring

      Remove the 2 fuel tube joint clips and pull out the 2 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. B001A17E03
      Text in Illustration
      *1 Fuel Tank Main Tube Sub-assembly
      *2 Fuel Tank Return Tube Sub-assembly

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

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

  24. REMOVE FUEL HOSE (for Double Tank Type)


    1. B0018UW

      for G.C.C. Countries:

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

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


    1. B00188CE07
      Text in Illustration
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-Ring

      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. B0019FIE04
      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. B0018O8E04
      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.

  26. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

  27. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. B0019SX

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

  28. REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    1. B001ARTE04
      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.