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FUEL TANK REMOVAL

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  1. Click here

    DISCHARGE FUEL SYSTEM PRESSURE

    (Click here)

  2. Click here

    REMOVE FUEL TANK CAP ASSEMBLY

  3. Click here

    REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. A0159U3

      Remove the 5 bolts and fuel tank protector.

  4. Click here

    DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01556FE03

      Detach the fuel tube clamp.

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

      Table 1. Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
  5. Click here

    DRAIN FUEL


    1. Connect the cable to the negative (-) battery terminal.

    2. Connect the GTS to the DLC3.

    3. Turn the ignition switch to ON.

      Note:

      Do not start the engine.

    4. Turn the GTS on.

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

      CAUTION:

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

      • Secure good ventilation.

      • Keep gasoline away from rubber or leather parts.

      A015626E01
      Tip:

      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.

      Table 2. Text in Illustration
      *1 Port
  6. Click here

    PRECAUTION

    Note:

    After turning the ignition 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).

  7. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

  8. Click here

    REMOVE REAR NO. 1 SEAT ASSEMBLY RH (for 60/40 Split Seat Type 40 Side)

    (Click here)

  9. Click here

    REMOVE REAR NO. 1 SEAT ASSEMBLY LH (for 60/40 Split Seat Type 60 Side)

    (Click here)

  10. Click here

    REMOVE REAR NO. 2 SEAT ASSEMBLY


  11. Click here

    REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH


  12. Click here

    REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH


  13. Click here

    REMOVE FRONT FLOOR CARPET ASSEMBLY


    1. Turn over the floor carpet.

      w/ Rear Air Conditioning System:

      Tip:

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

      w/o Rear Air Conditioning System:

      Tip:

      Fold back the floor carpet so that the service hole cover can be removed.

  14. Click here

    REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. A01582Q

      w/ Rear Air Conditioning System:

      Remove the 2 screws and air duct.

    2. A015B1D

      Remove the service hole cover.

    3. A0159RI

      Disconnect the fuel pump and sender gauge connector.

  15. Click here

    DISCONNECT FUEL TANK RETURN TUBE


    1. A0158Q6E03

      Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect 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.

      Table 3. Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
  16. Click here

    DISCONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY


    1. A0156ZFE03

      Detach the fuel tube clamp.

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

      Table 4. Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
  17. Click here

    DISCONNECT NO. 2 FUEL TANK BREATHER TUBE


    1. A015DA8E03

      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.

      Table 5. Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
  18. Click here

    DISCONNECT FUEL TANK BREATHER TUBE


    1. A0157KPE03

      Detach the fuel tube clamp.

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

      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.

      Table 6. Text in Illustration
      *1 Retainer
  19. Click here

    DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A015875

      Disconnect the hose from the filler pipe.

  20. Click here

    REMOVE FUEL TANK SUB-ASSEMBLY


    1. Place an engine lifter under the fuel tank.

    2. A0159SZ

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

    3. Slowly lower the engine lifter slightly.

  21. Click here

    REMOVE FUEL TANK MAIN TUBE, FUEL TANK RETURN TUBE AND NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A015C5UE04

      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.

      Table 7. Text in Illustration
      *1 Tube Joint
      *2 Tube Joint Clip
      *3 Fuel Tank Tube
      *4 O-Ring
      *5 Fuel Suction Plate
    2. A015C3W

      Remove the 3 fuel tubes from the fuel tank.

  22. Click here

    REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. A015837E01

      Set SST on the retainer.

      09808-14030
      Tip:

      • Securely attach the claws of SST to the protrusion of the retainer and fix SST in place.

      • Install SST while pressing the claws of SST against the retainer (towards the center of SST).

    2. A01573CE01

      Using SST, loosen the retainer.

      09808-14030
      Table 8. Text in Illustration
      A015DIT Turn
      Note:

      • Do not use any tools other than those specified in this operation. Damage to the retainer or the fuel tank may result.

      • While pressing down on SST so that the claws of SST do not slip off the protrusion of the retainer, turn the retainer counterclockwise to loosen it.

      Tip:

      The protrusion of the retainer fits in the ends of SST.

    3. Remove the retainer while holding the fuel suction tube assembly by hand.

    4. Remove the gasket from the fuel tank.

  23. Click here

    REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A015DXT

      Remove the hose from the fuel tank.

  24. Click here

    REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    1. A015A7OE01

      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.