FUEL TANK REMOVAL


  1. REMOVE REAR SEAT CUSHION ASSEMBLY


    1. for Sedan:

      Remove the rear seat cushion assembly Click here.

    2. for Wagon:

      Remove the rear seat cushion assembly Click here.

  2. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A00E9ND

      Remove the butyl tape and service hole cover.

    2. Disconnect the fuel sender gauge connector.

  3. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A00E78OE01
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Tank Vent Tube

      Remove the tube joint clip and pull out the fuel tank main tube.

      Note


      • Remove any dirt and foreign matter on the fuel tube joint before performing this work.

      • Do not scratch or allow any foreign matter to adhere to 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 after disconnecting the fuel tube.

  4. DISCONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A00E9X9E01
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Tank Vent Tube

      Remove the tube joint clip and pull out the fuel tank return tube.

      Note


      • Remove any dirt and foreign matter on the fuel tube joint before performing this work.

      • Do not scratch or allow any foreign matter to adhere to 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 after disconnecting the fuel tube.

  5. REMOVE TANK SUCTION TUBE SUPPORT


    1. A00EA72

      Press on the tabs from both sides of the tube.

    2. Pull on the tube in the direction indicated by the arrow in the illustration.

    3. A00EAWS

      Detach the 2 claws and remove the suction tube support.

  6. REMOVE FUEL PUMP GAUGE RETAINER


    1. A00E8URE02

      Using a 6 mm socket, install SST to the fuel pump gauge retainer.

      SST
      09808-14020

      Tech Tips


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

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

    2. A00E95XE02

      Using SST, loosen the fuel pump gauge retainer.

      Note


      • Do not use any tools other than those specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.

      • Loosen the retainer by turning it counterclockwise while holding SST down. Do not allow the protrusions of the fuel tank vent tube to slip out of their notches on the fuel tank.

      Tech Tips

      The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

    3. Remove the fuel pump gauge retainer while holding the fuel tank vent tube by hand.

  7. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. Remove the fuel tank vent tube from the fuel tank.

      Note

      Make sure that the fuel sender gauge arm does not bend.

    2. A00EAPVE02
      Text in Illustration
      *1 Gasket

      Remove the gasket from the fuel tank.

  8. DRAIN FUEL

  9. REMOVE TAILPIPE ASSEMBLY


    1. Remove the 2 bolts and 2 compression springs.

    2. Disconnect the tailpipe from the 4 exhaust pipe supports.

    3. Remove the gasket.

  10. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A00EA56

      Remove the 3 bolts and protector.

  11. REMOVE REAR FLOOR SIDE MEMBER COVER RH


    1. A00EADC

      Remove the clip, 2 grommets and rear floor side member cover RH.

  12. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A00EB1I

      Loosen the hose clamp bolt, and then disconnect the filler pipe hose from the fuel tank.

  13. REMOVE FUEL TANK ASSEMBLY


    1. A00E8F7

      Loosen the hose clamp bolt, and then disconnect the breather hose.

    2. A00EAJH

      Remove the 2 bolts and disconnect the parking brake cable.

    3. Disconnect the fuel tank return tube.


      1. A00E8UIE01

        Pinch the tabs of the retainer of the fuel tube connector to detach the lock claws and push the retainer down as shown in the illustration.

      2. Pull the fuel tank return tube off of the pipe.

        Note


        • Remove any dirt or foreign objects on the fuel tube connector before starting this step.

        • Do not scratch or allow foreign matter to adhere to the parts when disconnecting the fuel tube connector as the fuel tube connector contains the O-ring that seals the pipe.

        • Perform this work by hand. Do not use any other tools.

        • Do not forcibly bend, kink or turn the nylon tube.

        • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank return tube.

        • If the fuel tube connector and pipe are stuck, push and pull the connector to disconnect it.

    4. Disconnect the fuel tank main tube.


      1. A00EALVE01

        Pinch the tabs of the retainer of the fuel tube connector to detach the lock claws and push the retainer down as shown in the illustration.

      2. Pull the fuel tank main tube off of the pipe.

        Note


        • Remove any dirt or foreign objects on the fuel tube connector before starting this step.

        • Do not scratch or allow foreign matter to adhere to the parts when disconnecting the fuel tube connector as the fuel tube connector contains the O-ring that seals the pipe.

        • Perform this work by hand. Do not use any other tools.

        • Do not forcibly bend, kink or turn the nylon tube.

        • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank main tube.

        • If the fuel tube connector and pipe are stuck, push and pull the connector to disconnect it.

    5. Using a transmission jack, support the fuel tank.

    6. A00EATQ

      Remove the 4 bolts and 2 fuel tank bands.

    7. Lower the transmission jack to remove the fuel tank.

      Note


      • Do not drop the fuel tank.

      • When removing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

  14. REMOVE FUEL TANK CUSHION


    1. A00E6Q2E01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion

      Remove the No. 1 fuel tank cushion and 3 No. 2 fuel tank cushions.

  15. REMOVE FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A00E9L6

      Detach the 2 clamps and remove the fuel tank return tube.

  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A00E8HI

      Detach the 2 clamps and remove the fuel tank main tube.