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FUEL TANK REMOVAL

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  1. Click here

    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.

      Tip:

      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. 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 (for Single Tank Type)


    1. A015CF0E02

      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

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


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

    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.

      A015AJLE02
      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 3. Text in Illustration
      *1 Port
      *a for Single Tank Type
      *b for Double Tank Type

    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

      Disconnect the fuel pump and fuel sender gauge connector.

      Table 4. Text in Illustration
      *a for Single Tank Type
      *b for Double Tank Type
  7. Click here

    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. 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).

  9. Click here

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

    (Click here)

  10. Click here

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

    (Click here)

  11. Click here

    REMOVE REAR NO. 2 SEAT ASSEMBLY


  12. Click here

    REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH


  13. Click here

    REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH


  14. Click here

    REMOVE FRONT FLOOR CARPET ASSEMBLY


    1. Turn over the floor carpet.

      Tip:

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

  15. 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.

  16. Click here

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


    1. A015723E02

      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 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
  17. Click here

    DISCONNECT FUEL TANK RETURN TUBE (for Single Tank Type)


    1. A015E4OE03

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

    DISCONNECT FUEL TANK RETURN TUBE (for Double Tank Type)


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

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


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

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


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

    DISCONNECT FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. A015E7ME02

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

      Table 10. Text in Illustration
      *1 Retainer
  22. Click here

    DISCONNECT FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. A015B1HE02

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

      Table 11. Text in Illustration
      *1 Retainer
  23. Click here

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


    1. A015BQ9

      Disconnect the hose from the filler pipe.

  24. Click here

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


    1. A015875

      Disconnect the hose from the filler pipe.

  25. 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.

  26. Click here

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


    1. A015DAPE02

      Remove the 2 fuel tube joint clips and pull out the 2 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 12. Text in Illustration
      *1 Tube Joint
      *2 Tube Joint Clip
      *3 Fuel Tank Tube
      *4 O-Ring
      *5 Fuel Suction Plate
    2. A0155U5

      Remove the 2 fuel tubes from the fuel tank.

  27. Click here

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


    1. A015C5UE03

      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 13. 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.

  28. Click here

    REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. A015B6RE01

      Set SST on the fuel pump gauge retainer.

      09808-14030
      Tip:

      • 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 retainer.

      09808-14030
      Table 14. Text in Illustration
      A015DIT Turn
      Note:

      • When the 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.

      Tip:

      Fit the tips of SST onto the ribs of the retainer.

    3. Remove the 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.

  29. Click here

    REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A015DXT

      Remove the hose from the fuel tank.

  30. 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.