FUEL TANK(w/o Canister Pump Module) REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work.

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  3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

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  4. REMOVE FRONT FLOOR COVER CENTER LH

    B002I11

    1. Remove the bolt, 2 nuts and 6 clips from the front floor cover center LH.

    2. B002HC6

      Loosen the nut and remove the front floor cover center LH.

  5. REMOVE NO. 2 FLOOR UNDER COVER


    1. B002J73

      Detach the clip and remove the 2 nuts and No. 2 floor under cover.

  6. DISCONNECT NO. 1 FUEL EVAPORATION TUBE


    1. B002I4O

      Slide the hose clamp, and disconnect the No. 1 fuel evaporation tube from the fuel pipe.

  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B002H62

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

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  8. REMOVE FUEL HOSE PROTECTOR


    1. B002J61

      Detach the claw and remove the fuel hose protector from the fuel tank assembly and fuel tank to filler pipe hose.

  9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B002INV

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

  10. DISCONNECT CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY


    1. B002KI6

      Disconnect the clamp from the No. 2 fuel tank band.

    2. B002HAG

      Slide the hose clamp, then disconnect the charcoal canister outlet tube sub-assembly from the fuel tank breather tube.

  11. REMOVE FUEL TANK ASSEMBLY


    1. B002KAU

      Disconnect the 3 wire harness clamps from the 2 No. 4 fuel tube clamps and the bracket on the vehicle side.

    2. Using an engine lifter and attachments, support the fuel tank assembly.

    3. B002HJ5

      Remove the 2 bolts and No. 1 fuel tank band.

    4. Remove the 2 bolts and No. 2 fuel tank band.

    5. Slightly lower the engine lifter.

      Note

      Be careful not to cut the wiring.

    6. B002HC4

      Disconnect the No. 3 fuel tank breather tube sub-assembly from the fuel tank assembly.

    7. B002HE0

      Disconnect the fuel pump connector and fuel sender gauge assembly connector.

      Note


      • Before starting the operation, check that there is no mud or other dirt on the connector.

      • Do not use any tools.

    8. Disconnect the 3 wire harness clamps from the 3 No. 4 fuel tube clamps.

  12. DISCONNECT FUEL EMISSION HOSE

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  13. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

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  14. REMOVE FUEL TANK VENT TUBE SET PLATE

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  15. REMOVE FUEL SUCTION TUBE ASSEMBLY

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  16. REMOVE FUEL SENDER GAUGE ASSEMBLY

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  17. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B002K87C02
      *1 Fuel Tank Main Tube Sub-assembly
      *2 No. 1 Fuel Evaporation Tube Sub-assembly

      Disconnect the 5 clamps and remove the fuel tank main tube sub-assembly from the 5 No. 4 fuel tube clamps.

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


    1. Disconnect the 4 clamps and remove the No. 1 fuel evaporation tube sub-assembly from the 4 No. 4 fuel tube clamps.

  19. REMOVE CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY


    1. B002K7Y

      Disconnect the 3 clamps and remove the charcoal canister outlet tube sub-assembly from the 3 No. 4 fuel tube clamps.

  20. REMOVE NO. 4 FUEL TUBE CLAMP


    1. B002IBV

      Remove the 8 No. 4 fuel tube clamps from the fuel tank assembly.

  21. REMOVE FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. B002IMR

      Remove the fuel evaporation tube sub-assembly from the fuel tank assembly.

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