FUEL TANK REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:


    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.

    • After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.


    1. Disconnect the fuel pump ECU connector Click here.

    2. Start the engine. After the engine stops, turn the engine switch off.

      Tech Tips

      DTC P0171/0174 (system too lean) may be stored.

    3. Crank the engine again, and then check that the engine does not start.

    4. Loosen the fuel tank cap, and then discharge the pressure in the fuel tank completely.

    5. Disconnect the cable from the negative (-) battery terminal.

      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 Click here.

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

    6. Connect the fuel pump ECU connector Click here.

  2. REMOVE FUEL TANK CAP ASSEMBLY

  3. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. A0159U3

      Remove the 5 bolts and No. 1 fuel tank protector sub-assembly.

  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. A01587QE01
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      A015DIT Pull Up

      Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the fuel tank main tube sub-assembly.

      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.

  5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)

    A015BNDE01
    Text in Illustration
    *1 Retainer *2 Pipe
    *3 Nylon Tube *4 Connector
    *5 O-Ring - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    A015DIT Pull Up - -

    1. Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the fuel tank main tube sub-assembly.

      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.

  6. DRAIN FUEL


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

    2. Connect the GTS to the DLC3.

    3. Turn the engine switch on (IG).

      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.

      Tech Tips

      If the fuel pump does not operate, remove the tube joint clip and disconnect the fuel tank return tube sub-assembly, and drain fuel from the port shown in the illustration.

      A015AJLE03
      Text in Illustration
      *a for Single Tank Type
      *b for Double Tank Type
      *c Port

    6. Disconnect the cable from the negative (-) battery terminal.

      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 Click here.

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

    7. A015DW4E02
      Text in Illustration
      *a for Single Tank Type
      *b for Double Tank Type

      Disconnect the fuel pump and fuel sender gauge connector.

  7. 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 Click here.

  8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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

    Click here

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

    Click here

  11. REMOVE REAR NO. 2 SEAT ASSEMBLY


  12. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH


  13. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH


  14. REMOVE FRONT FLOOR CARPET ASSEMBLY

    A015BD7

    1. Turn over the floor carpet.

      Tech Tips

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

  15. 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 rear floor No. 2 service hole cover.

  16. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. A015DRBE01
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      A015DIT Pull Up

      Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the No. 2 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.

  17. DISCONNECT NO. 2 FUEL TANK BREATHER HOSE (for Double Tank Type)


    1. A0159A3

      for G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Slide the clip and disconnect the No. 2 fuel tank breather hose from the pipe.

  18. DISCONNECT FUEL TANK RETURN TUBE (for Single Tank Type)


    1. A0159MWE01
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      A015DIT Pull Up

      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.

  19. DISCONNECT FUEL TANK RETURN TUBE (for Double Tank Type)

    A0159OPE01
    Text in Illustration
    *1 Retainer *2 Pipe
    *3 Nylon Tube *4 Connector
    *5 O-Ring - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    A015DIT Pull Up - -

    1. 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.

  20. DISCONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. A0159XBE01
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      A015DIT Pull Up

      for G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Pull up the retainer and disconnect the No. 1 fuel emission tube sub-assembly.

        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.

    2. A015E5TE01
      Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
      A015DIT Push
      A015CC1 Pull Up

      except G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Pull the retainer up while pinching it on both sides by hand as shown in the illustration, and disconnect the No. 1 fuel emission tube sub-assembly.

        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.

  21. DISCONNECT FUEL HOSE (for Double Tank Type)


    1. A015AJ4

      for G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Slide the clip and disconnect the fuel hose from the pipe.

  22. DISCONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)

    A01586GE01
    Text in Illustration
    *1 Retainer *2 Connector
    *3 O-Ring *4 Pipe
    *5 Nylon Tube - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    A015DIT Pull Up - -

    1. Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the No. 2 fuel tank main tube sub-assembly.

      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.

  23. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. A0159BTE01
      Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
      A015DIT Pull Up

      except G.C.C. Countries:


      1. Detach the fuel tube clamp.

      2. Pull up the retainer and disconnect the No. 2 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.

  24. DISCONNECT FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. A015D3EE01
      Text in Illustration
      *1 Retainer
      A015DIT Pull Up

      Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the fuel tank breather tube from the fuel tank to filler pipe sub-assembly.

      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-ring or cause leaks in the seal between the pipe and connector.

  25. DISCONNECT FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. A015BX4E01
      Text in Illustration
      *1 Retainer
      A015DIT Pull Up

      Detach the fuel tube clamp.

    2. Pull up the retainer and disconnect the fuel tank breather tube from the fuel tank to filler pipe sub-assembly.

      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-ring or cause leaks in the seal between the pipe and connector.

  26. DISCONNECT FUEL TANK TO FILLER PIPE HOSE (for Single Tank Type)


    1. A015BQ9

      Loosen the hose clamp and disconnect the fuel tank to filler pipe hose from the fuel tank to filler pipe sub-assembly.

  27. DISCONNECT FUEL TANK TO FILLER PIPE HOSE (for Double Tank Type)


    1. A015875

      Loosen the hose clamp and disconnect the fuel tank to filler pipe hose from the fuel tank to filler pipe sub-assembly.

  28. REMOVE FUEL TANK SUB-ASSEMBLY


    1. Place an engine lifter under the fuel tank sub-assembly.

    2. A0159SZ

      Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank band sub-assemblies.

    3. Slowly lower the engine lifter slightly.

  29. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. A015DAPE03
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Suction Plate Sub-assembly

      Remove the 2 tube joint clips and pull out the 2 fuel tube joints.

      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.

    2. A0155PCE01
      Text in Illustration
      *1 Fuel Tank Main Tube Sub-assembly
      *2 Fuel Tank Return Tube Sub-assembly

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

    3. Detach the clamp and remove the fuel tank return tube sub-assembly.

  30. REMOVE FUEL HOSE (for Double Tank Type)


    1. A015AQ7

      for G.C.C. Countries:

      Slide the clip and remove the fuel hose from the fuel suction tube sub-assembly.

  31. REMOVE FUEL TANK MAIN TUBE, FUEL TANK RETURN TUBE AND NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. A015C5UE05
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Suction Plate Sub-assembly

      Remove the 3 tube joint clips and pull out the 3 fuel tube joints.

      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.

    2. A0157Z2E01
      Text in Illustration
      *1 Fuel Tank Main Tube Sub-assembly
      *2 Fuel Tank Return Tube Sub-assembly
      *3 No. 2 Fuel Tank Main Tube Sub-assembly

      except G.C.C. Countries:


      1. Detach the clamp and remove the fuel tank main tube sub-assembly.

      2. Detach the clamp and remove the fuel tank return tube sub-assembly.

      3. Detach the 2 clamps and remove the No. 2 fuel tank main tube sub-assembly.

    3. A0158VWE01
      Text in Illustration
      *1 Fuel Tank Main Tube Sub-assembly
      *2 Fuel Tank Return Tube Sub-assembly
      *3 No. 2 Fuel Tank Main Tube Sub-assembly

      for G.C.C. Countries:


      1. Detach the clamp and remove the fuel tank main tube sub-assembly.

      2. Detach the clamp and remove the fuel tank return tube sub-assembly.

      3. Detach the 2 clamps and remove the No. 2 fuel tank main tube sub-assembly.

  32. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. A015B6RE01

      Set SST on the fuel pump gauge retainer.

      SST
      09808-14030

      Tech Tips


      • Engage the claws of SST securely with the fuel pump gauge retainer holes to secure SST.

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

    2. A015BTRE01

      Using SST, loosen the fuel pump gauge retainer.

      SST
      09808-14030
      Text in Illustration
      A015DIT Turn

      Note


      • When the fuel pump gauge retainer is loosened, be careful as the pump and gauge tube will spring upward from the force of the spring.

      • Remove foreign matter around the fuel suction with pump and gauge before this operation.

      Tech Tips

      Fit the tips of SST onto the ribs of the fuel pump gauge retainer.

    3. Remove the fuel pump gauge retainer.

    4. Remove the fuel suction with pump and gauge tube assembly from the fuel tank.

      Note

      Be careful not to bend the arm of the fuel sender gauge.

    5. Remove the gasket from the fuel tank.

  33. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A015DXT

      Loosen the hose clamp and remove the fuel tank to filler pipe hose from the fuel tank sub-assembly.

  34. REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    1. A015C9HE01
      Text in Illustration
      *a for G.C.C. Countries

      Remove the fuel tube clamp from the No. 1 fuel tank heat insulator.

    2. Using needle-nose pliers, remove the 4 clips shown in the illustration, and then remove the No. 1 fuel tank heat insulator.