FUEL TANK REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge the fuel system pressure Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    Note


    • w/ Navigation System:

      After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.

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

  3. REMOVE REAR SEAT ASSEMBLY


    1. Remove the rear No. 1 seat assembly and rear No. 2 seat assembly Click here.

  4. REMOVE FRONT FLOOR CARPET ASSEMBLY

    A01ENZ8

    1. Turn over the floor carpet.

      Tech Tips

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

  5. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. A01ENBP

      Remove the 2 screws and air duct.

    2. A01ERT5

      Remove the service hole cover.

  6. REMOVE FUEL TANK CAP ASSEMBLY

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


    1. A01EORM

      Remove the 5 bolts and fuel tank protector.

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


    1. A01ERD3E01

      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.

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


    1. A01ESOYE01

      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.

  10. DRAIN FUEL


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

      Note

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

    2. Connect the intelligent tester to the DLC3.

    3. Turn the engine switch on (IG).

      Note

      Do not start the engine.

    4. Turn the intelligent tester 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 fuel tube joint clip and disconnect the fuel tank return tube, and drain fuel from the port shown in the illustration.

      A01EO3OE01

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

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

      Note


      • w/ Navigation System:

        After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.

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

    7. A01EO16E01

      Disconnect the fuel pump and fuel sender gauge connector.

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


    1. A01EPPSE01

      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.

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


    1. A01EOD7E02

      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.

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


    1. A01ENMDE01

      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.

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


    1. A01ESN4E01

      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.

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


    1. A01ERQTE01

      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.

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


    1. A01EQNNE01

      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.

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


    1. A01ES6NE01

      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.

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


    1. A01ENX7

      Disconnect the hose from the filler pipe.

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


    1. A01EN5N

      Disconnect the hose from the filler pipe.

  20. REMOVE FUEL TANK SUB-ASSEMBLY


    1. Place a transmission jack under the fuel tank.

    2. A01EQUE

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

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


    1. A01EQHQE01

      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.

    2. A01ESMY

      Remove the 2 fuel tubes from the fuel tank.

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


    1. A01EOYQE02

      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.

    2. A01ER11

      Remove the 3 fuel tubes from the fuel tank.

  23. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. A01ENUNE01

      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. A01EPK8

      Using SST, loosen the retainer.

      SST
      09808-14030
      Text in Illustration
      A01EO1M Turn

      Tech Tips

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

      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.

    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.

  24. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A01ER47

      Remove the hose from the fuel tank.

  25. REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    1. A01EQMFE01

      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.