FUEL TANK 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 remove the 2 nuts and No. 2 floor under cover.

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


    1. B0057J3

      Slide the clamp and disconnect the No. 1 fuel evaporation tube sub-assembly from the fuel tank to canister tube.

  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B0057U9

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

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  8. REMOVE FUEL HOSE PROTECTOR


    1. B0059YL

      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. B005A6I

      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. B0059R5

      Detach the clamp and disconnect the charcoal canister outlet tube sub-assembly from the No. 2 fuel tank band sub-assembly.

    2. B00587B

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

  11. DISCONNECT NO. 3 FUEL TANK BREATHER TUBE SUB-ASSEMBLY


    1. B0059GI

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

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  12. REMOVE FUEL TANK ASSEMBLY


    1. B00594V

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

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

    3. B005AJO

      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. B0058HS

      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 EMISSION HOSE

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  14. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

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  15. REMOVE FUEL TANK VENT TUBE SET PLATE

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  16. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP

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  17. REMOVE FUEL SENDER GAUGE ASSEMBLY

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  18. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B005950C02
      *1 No. 1 Fuel Evaporation Tube Sub-assembly
      *2 Fuel Tank Main Tube Sub-assembly
      *3 No. 3 Fuel Tube Clamp
      *4 No. 4 Fuel Tube Clamp
      *5 No. 5 Fuel Tube Clamp

      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.

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


    1. Disconnect the 5 clamps and remove the No. 1 fuel evaporation 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.

  23. REMOVE CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY


    1. B005AJE

      Disconnect the 2 clamps and remove the charcoal canister outlet tube sub-assembly from the 2 No. 2 fuel tube clamps.

  24. REMOVE NO. 2 FUEL TUBE CLAMP


    1. B005793

      Remove the 2 No. 2 fuel tube clamps from the fuel tank assembly.

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


    1. B0057E0

      Remove the No. 1 fuel evaporation tube sub-assembly from the fuel tank assembly.

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