FUEL TANK (for 5 Door) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  2. REMOVE REAR SEAT ASSEMBLY LH


    1. for 60/40 Split Double-folding Seat Type LH Side:

      Remove the rear seat assembly LH Click here.

    2. for 60/40 Split Slide Walk-in Seat Type LH Side:

      Remove the rear seat assembly LH Click here.

  3. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A00O3HR

      Remove the 3 screws and rear floor service hole cover.

    2. A00O3VOE01
      Text in Illustration
      *A for Single Tank Type
      *B for Double Tank Type

      Disconnect the fuel pump and sender gauge connector.

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


    1. A00O8I4

      Remove the 6 bolts and No. 1 fuel tank protector.

    2. A00O81H

      for Half Cover Type:

      Remove the 4 bolts and No. 1 fuel tank protector.

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

    A00O72S

  6. DISCONNECT FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)

    A00O3AR

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

    A00O4V7

  8. DISCONNECT FUEL CUT OFF TUBE (for Single Tank Type)

    A00O31T

  9. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. A00OAWJ

      Disconnect the fuel tank breather tube Click here.

  10. DISCONNECT NO. 4 FUEL MAIN TUBE SUB-ASSEMBLY AND FUEL SUCTION TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. A00OA8N

      Disconnect the No. 4 fuel main tube and fuel suction tube Click here.

  11. DISCONNECT FUEL CUT OFF TUBE (for Double Tank Type)


    1. A00O4AJ

      Disconnect the fuel cut off tube Click here.

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


    1. A00O6VV

      Disconnect the fuel return tube and No. 2 fuel main tube Click here.

  13. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. A00OBGN

      Disconnect the fuel tank breather tube Click here.

  14. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A00O7M7

      Disconnect the fuel tank to filler pipe hose from the filler pipe.

  15. REMOVE FUEL TANK SUB-ASSEMBLY


    1. Place a transmission jack under the fuel tank.

    2. A00O8OZ

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

    3. Slowly lower the transmission jack slightly.

  16. REMOVE FUEL TANK CUSHION


    1. A00O50JE01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion
      *3 No. 3 Fuel Tank Cushion

      Remove the No. 1, No. 2 and No. 3 fuel tank cushions from the fuel tank.

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


    1. A00O9NEE01
      Text in Illustration
      *1 Fuel Tube
      *2 Fuel Tube Joint
      *3 Fuel Tube Joint Clip
      *4 O-Ring

      Remove the 2 fuel tube joint clips and pull out the fuel return tube and fuel tank main tube.

      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. A00O32R

      Remove the fuel return tube and fuel tank main tube from the fuel tank.

  18. REMOVE NO. 4 FUEL MAIN TUBE SUB-ASSEMBLY AND FUEL SUCTION TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. A00O47IE01
      Text in Illustration
      *1 Fuel Tube
      *2 Fuel Tube Joint
      *3 Fuel Tube Joint Clip
      *4 O-Ring

      Remove the 2 fuel tube joint clips and pull out the No. 4 fuel main tube and fuel suction tube.

      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. A00O76F

      Detach the clamp and remove the No. 4 fuel main tube from the fuel tank.

    3. Detach the clamp and remove the fuel suction tube from the fuel tank.

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


    1. A00OBAOE01
      Text in Illustration
      *1 Fuel Tube
      *2 Fuel Tube Joint
      *3 Fuel Tube Joint Clip
      *4 O-Ring

      Remove the 3 fuel tube joint clips and pull out the fuel tank main tube, fuel return tube and No. 2 fuel main tube.

      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. A00O524

      Detach the clamp and remove the No. 2 fuel main tube from the fuel tank.

    3. Detach the clamp and remove the fuel return tube from the fuel tank.

    4. Remove the fuel tank main tube from the fuel tank.

  20. REMOVE FUEL TANK VENT TUBE ASSEMBLY (for Single Tank Type)


    1. A00O6S1E01

      Set SST on the retainer.

      SST
      09808-14030

      Tech Tips


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

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

    2. A00OAZ1E01

      Using SST, loosen the retainer.

      SST
      09808-14030
      Text in Illustration
      A00O9VA Turn

      Tech Tips

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

      Note


      • When the retainer is loosened, be careful as the fuel tank vent tube will spring upward from the force of the spring.

      • Remove any foreign matter around the fuel tank vent tube before this operation.

    3. Remove the retainer.

    4. Remove the fuel tank vent 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.

  21. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (for Double Tank Type)


    1. A00JUR3E01

      Set SST on the retainer.

      SST
      09808-14030

      Tech Tips


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

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

    2. A00JVH4E01

      Using SST, loosen the retainer.

      SST
      09808-14030
      Text in Illustration
      A00JWY4 Turn

      Tech Tips

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

      Note


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

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

    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.

  22. REMOVE NO. 3 FUEL TANK PROTECTOR


    1. A00OAOR

      Remove the 2 bolts.

    2. Detach the 4 clamps and remove the No. 3 fuel tank protector.

  23. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A00O7I7

      Remove the fuel tank to filler pipe hose from the fuel tank.