FUEL TANK(w/ Canister Pump Module) REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. 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.

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  3. DISCONNECT CABLE FROM NEGATIVE 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

    B005859

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

    2. B0057C3

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

  5. REMOVE NO. 2 FLOOR UNDER COVER


    1. B0058SZ

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

  6. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY


    1. B0057MF

      Disconnect the connector from the charcoal canister assembly.

    2. Detach the 3 clamps and disconnect the fuel gauge wire.

    3. B0058SK

      Disconnect the fuel tank to canister tube sub-assembly from the charcoal canister assembly.

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  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B005837

      Disconnect the 2 fuel tank main tube sub-assemblies from the 2 fuel pipes.

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  8. REMOVE FUEL HOSE PROTECTOR


    1. B005AFC

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

  9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B005AJW

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

  10. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY


    1. B005AZT

      Detach the clamp and disconnect the fuel tank vent hose sub-assembly from the No. 2 fuel tank band sub-assembly.

  11. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY


    1. B0058QN

      Disconnect the fuel tank breather tube sub-assembly from the fuel tank filler pipe sub-assembly.

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  12. REMOVE FUEL TANK ASSEMBLY


    1. B0059BK

      Disconnect the 3 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. B0058V6

      Remove the 2 bolts and No. 1 fuel tank band sub-assembly.

    4. Remove the 4 bolts and 2 No. 2 fuel tank band sub-assemblies.

    5. Slightly lower the engine lifter.

      Note

      Be careful not to cut the fuel gauge wire.

    6. B00595Z

      Disconnect the 2 connectors from the fuel sender gauge assembly and fuel suction tube assembly with pump.

      Note


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

      • Do not use any tools.

    7. Detach the 3 clamps from the No. 3 fuel tube clamp, No. 4 fuel tube clamp and No. 5 fuel tube clamp, and disconnect the fuel gauge wire from the fuel tank assembly.

  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 WITH PUMP

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  16. REMOVE FUEL SENDER GAUGE ASSEMBLY

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  17. REMOVE FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY


    1. B0058LY

      Remove the fuel tank to canister tube sub-assembly from the fuel tank assembly.

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  18. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY


    1. B0058N7

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

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  19. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B0057TV

      Disconnect the 5 clamps and remove the fuel tank main tube sub-assembly from the No. 3 fuel tube clamp, 3 No. 4 fuel tube clamps and No. 5 fuel tube clamp.

  20. REMOVE NO. 3 FUEL TUBE CLAMP


    1. Remove the No. 3 fuel tube clamp from the fuel tank assembly.

  21. REMOVE NO. 4 FUEL TUBE CLAMP


    1. Remove the 3 No. 4 fuel tube clamps from the fuel tank assembly.

  22. REMOVE NO. 5 FUEL TUBE CLAMP


    1. Remove the No. 5 fuel tube clamp from the fuel tank assembly.