FUEL TANK (for 5 Door) REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge the fuel system pressure Click here.

  2. 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.

  3. 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.

  4. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A00JTPK

      Remove the 3 screws and rear floor service hole cover.

    2. A00K1I5E01
      Text in Illustration
      *A for Single Tank Type
      *B for Double Tank Type

      Disconnect the fuel pump and sender gauge connector.

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


    1. A00JYRA

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

  6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A00JTNZ

      Disconnect the fuel tank main tube Click here.

  7. DRAIN FUEL


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

      Note

      Do not start the engine.

    3. Turn the intelligent tester on.

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

    5. Operate the fuel pump and drain the fuel from the fuel tank main tube.

      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.

  8. DISCONNECT FUEL RETURN TUBE SUB-ASSEMBLY


    1. A00K1XH

      Disconnect the fuel return tube Click here.

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


    1. A00JVM3

      Disconnect the fuel cut off tube Click here.

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


    1. A00JXFK

      Disconnect the fuel cut off tube Click here.

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


    1. A00JU70

      Disconnect the fuel tank breather tube Click here.

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


    1. A00JVXL

      Disconnect the fuel tank breather tube Click here.

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


    1. A00JTTI

      Disconnect the No. 2 fuel main tube Click here.

  14. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A00JUGG

      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. A00JY6A

      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. A00JUTPE01
      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 TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. A00JUE3E01
      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 tank main tube and fuel return 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. A00JV6K

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

  18. 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. A00JZS8E01
      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. A00JZOT

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

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

  19. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. A00JUR3E01

      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. 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.

  20. REMOVE NO. 3 FUEL TANK PROTECTOR


    1. A00JVSE

      Remove the 2 bolts.

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

  21. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A00JWDD

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