FUEL TANK REMOVAL

PROCEDURE

1. DISCHARGE FUEL SYSTEM PRESSURE

   (Click here)

2. REMOVE REAR SEAT ASSEMBLY LH

   (Click here)

3. REMOVE REAR FLOOR SERVICE HOLE COVER

   Tip:

   Fold back the floor mat so that the rear floor service hole cover can be removed.

   1. 

      Remove the 3 screws and rear floor service hole cover.

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

   1. 

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

5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

   1. 

      Disconnect the fuel tank main tube (Click here).

6. DRAIN FUEL

   1. Connect the GTS to the DLC3.

   2. Turn the engine switch on (IG).

      Note:

      Do not start the engine.

   3. Turn the GTS 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.

   6. 

      Disconnect the fuel pump and sender gauge connector.

7. 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 hereClick here).

8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

   Note:

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

9. DISCONNECT FUEL RETURN TUBE SUB-ASSEMBLY

   1. 

      Disconnect the fuel return tube (Click here).

10. DISCONNECT FUEL CUT OFF TUBE

    1. 

       Disconnect the fuel cut off tube (Click here).

11. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY

    1. 

       Disconnect the fuel tank breather tube (Click here).

12. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

    1. 

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

13. REMOVE FUEL TANK SUB-ASSEMBLY

    1. Place an engine lifter under the fuel tank.

    2. 

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

    3. Slowly lower the engine lifter slightly.

14. REMOVE FUEL TANK CUSHION

    1. 

       *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.

15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY

    1. 

       *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. 

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

16. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

17. REMOVE NO. 3 FUEL TANK PROTECTOR

    1. 

       Remove the 2 bolts.

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

18. REMOVE FUEL TANK TO FILLER PIPE HOSE

    1. 

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