FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. DRAIN FUEL

  3. REMOVE REAR FLOOR SIDE MEMBER COVER LH


  4. REMOVE REAR FLOOR SIDE MEMBER COVER RH


  5. REMOVE REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY (for Sedan)

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  6. REMOVE CENTER EXHAUST PIPE ASSEMBLY

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  7. REMOVE REAR NO. 1 FLOOR UNDER COVER (w/ Cover)


    1. A0030CI

      Remove the 4 clips and nut.

    2. Loosen the 2 grommets, then remove the rear No. 1 floor under cover.

  8. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. for Sedan:


      1. A0030GQ

        Remove the 3 bolts, nut and No. 1 fuel tank protector.

    2. except Sedan:


      1. A0030P9

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

  9. DISCONNECT FUEL TANK BREATHER TUBE


    1. A0030ZTC01
      *1 No. 1 Charcoal Canister Outlet Hose
      *2 Fuel Tank Breather Tube

      Loosen the clamp, then disconnect the fuel tank breather tube from the fuel tank filler pipe sub-assembly.

  10. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. Disconnect the No. 1 charcoal canister outlet hose from the fuel tank filler pipe sub-assembly.

  11. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A0030X6

      Loosen the clamp, then disconnect the fuel tank to filler pipe hose from the fuel tank assembly.

  12. DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A0030R0C02
      *a Fuel Pipe
      *b Rubber Hose
      *c Retainer
      *d O-ring
      A0030PX Turn
      A003094 Pull

      Turn the projections of the retainer to disengage the lock claws, and then pull off the No. 1 fuel evaporation tube sub-assembly.

      Note


      • Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the fuel pipe.

      • Only disconnect the fuel tube connector by hand.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

  13. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Type A:


      1. A003020C01
        *a Retainer
        *b Fuel Tube Connector
        *c Fuel Pipe
        *d O-ring
        A0030PX Push
        A003094 Pull Out
        A0030VP Pull Off

        Disengage the 2 claws of the retainer. Pull out the retainer as shown in the illustration.

      2. Disconnect the fuel tank main tube sub-assembly from the fuel pipe.

        Note


        • Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

        • Only disconnect the fuel tube connector by hand.

        • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.

        • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

    2. Type B:


      1. A0030AJC02
        *a Retainer
        *b Fuel Tube Connector Cover
        *c Fuel Tube Connector
        *d Fuel Pipe
        *e Nylon Tube
        *f O-ring

        Release the lock of the fuel tube connector cover as shown in the illustration, then pull off the fuel tank main tube sub-assembly.

        Note


        • Check that there are no scratches or foreign matter on the connecting parts of the fuel tube connector and fuel pipe before performing this work.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

        • Only disconnect the fuel tube connector by hand.

        • Do not forcibly bend, twist or turn the nylon tube.

        • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.

        • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

  14. REMOVE FUEL TANK ASSEMBLY


    1. A0030XE

      Remove the 2 bolts and disconnect the parking brake cable assembly.

    2. A0030GJC01
      *A for Sedan
      *B except Sedan

      Support the fuel tank assembly using an engine lifter.

      Tech Tips

      Using height adjustment attachments and plate lift attachments, place the fuel tank assembly horizontally.

    3. for Sedan:


      1. A002ZUH

        Remove the 4 bolts.

    4. except Sedan:


      1. A002ZWA

        Remove the 4 bolts and 2 fuel tank bands.

    5. Lower the engine lifter to remove the fuel tank assembly.

      Note


      • Do not drop the fuel tank assembly.

      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

  15. REMOVE NO. 1 FUEL TANK CUSHION


    1. A0030YTC01
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion

      Remove the No. 1 fuel tank cushion from the fuel tank assembly.

  16. REMOVE NO. 2 FUEL TANK CUSHION


    1. Remove the 3 No. 2 fuel tank cushions from the fuel tank assembly.

  17. REMOVE NO. 4 FUEL TANK CUSHION


    1. A00301A

      Remove the No. 4 fuel tank cushion from the fuel tank assembly.

  18. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A002ZP6C01
      *1 Fuel Tank Main Tube Sub-assembly

      Disengage the 2 claws to remove the fuel tank main tube sub-assembly from the fuel tank assembly.

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


    1. A0030E1C01
      *1 No. 1 Fuel Evaporation Tube Sub-assembly

      Disengage the 2 claws to remove the No. 1 fuel evaporation tube sub-assembly from the fuel tank assembly.

  20. REMOVE NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A003074

      Disconnect the clamp, and remove the No. 1 charcoal canister outlet hose from the fuel tank assembly.