FUEL TANK REMOVAL

PROCEDURE


  1. 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.

  2. REMOVE FUEL TANK CAP ASSEMBLY

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


    1. B001AFE

      Remove the 5 bolts and fuel tank protector.

  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B00194S

      Detach the fuel tube clamp.

    2. Disconnect the fuel tank main tube.

  5. DRAIN FUEL


    1. for Double Tank Type:


      1. Connect the GTS to the DLC3.

      2. Turn the engine switch to on (IG).

        Note

        Do not start the engine.

      3. Turn the GTS on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Intank Fuel Pump Relay.

        CAUTION:


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

        • Secure good ventilation.

        Tech Tips

        for Single Tank Type:

        Remove the fuel tube joint clip and disconnect the fuel tank return tube, and drain fuel from the port shown in the illustration.

        for Double Tank Type:

        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.

        B001878E05
        Text in Illustration
        *A for Single Tank Type
        *B for Double Tank Type
        *a Port

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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


    1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

  7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH

    Click here

  8. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH

    Click here

  9. REMOVE REAR NO. 1 SEAT PROTECTOR

    Click here

  10. REMOVE REAR NO. 2 SEAT PROTECTOR

    Click here

  11. REMOVE REAR STEP COVER

    Click here

  12. REMOVE REAR DOOR SCUFF PLATE LH

    Click here

  13. REMOVE REAR DOOR SCUFF PLATE RH

    Click here

  14. REMOVE REAR FLOOR MAT REAR SUPPORT PLATE

    Click here

  15. REMOVE AIR DUCT PLUG

    Click here

  16. REMOVE REAR AIR DUCT GUIDE

    Click here

  17. REMOVE FRONT FLOOR CARPET ASSEMBLY

    B00182Y

    1. Fold back the floor carpet.

      Tech Tips

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

  18. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. B0018LZ

      Remove the 2 screws and air duct.

    2. B0019W1

      Remove the service hole cover.

    3. B00187OE04
      Text in Illustration
      *A for Single Tank Type
      *B for Double Tank Type

      Disconnect the fuel pump and fuel sender gauge connector.

  19. DISCONNECT FUEL TANK RETURN TUBE


    1. B001ARGE02
      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 both ends of 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.

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


    1. B0018EX

      Detach the fuel tube clamp.

    2. Disconnect the No. 2 fuel tank breather tube from the body.

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


    1. B0018U5E06
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Connector
      *d Nylon Tube
      *e O-ring
      B0018FC Pull Up

      Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the fuel main 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.

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


    1. B00194QE07
      Text in Illustration
      *a Retainer
      *b Connector
      *c Pipe
      *d Nylon Tube
      *e O-ring
      B0018FC Pull Up

      Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the 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.

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


    1. B0019FDE03
      Text in Illustration
      *a Retainer

      Detach the fuel tube clamp.

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

      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-rings or cause leaks in the seal between the pipe and connector.

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


    1. B0019ACE05
      Text in Illustration
      *a Retainer

      Detach the fuel tube clamp.

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

      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-rings or cause leaks in the seal between the pipe and connector.

  25. DISCONNECT FUEL TANK TO FILLER PIPE HOSE (for Single Tank Type)


    1. B00196N

      Disconnect the hose from the filler pipe.

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


    1. B001A4A

      Disconnect the hose from the filler pipe.

  27. REMOVE FUEL TANK SUB-ASSEMBLY


    1. Place a engine lifter under the fuel tank.

    2. B001AIF

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

    3. Lower the engine lifter to remove the fuel tank from the vehicle.

      Note

      Do not allow the fuel tank to contact the vehicle, especially the differential.

      Tech Tips

      Lower the engine lifter slowly.

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


    1. B0018QYE03
      Text in Illustration
      *a Tube Joint
      *b Fuel Tank Tube
      *c Tube Joint Clip
      *d Fuel Suction Plate
      *e O-ring

      Remove the 2 fuel tube joint clips and pull out the 2 fuel tubes.

      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. B001AZC

      Remove the 2 fuel tubes from the fuel tank.

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


    1. B001A45E03
      Text in Illustration
      *a Tube Joint
      *b Fuel Tank Tube
      *c Tube Joint Clip
      *d Fuel Suction Plate
      *e O-ring

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

      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. B001836

      Remove the 3 fuel tubes from the fuel tank.

  30. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

  31. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. B0019SX

      Remove the hose from the fuel tank.

  32. REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    1. B00194XE03

      Remove the fuel tube clamp from the heat insulator.

    2. Using needle-nose pliers, remove the 4 clips shown in the illustration and then remove the heat insulator.