FUEL TANK REMOVAL

PROCEDURE

  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. PRECAUTION

    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.

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  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

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  4. DRAIN FUEL

  5. DISCONNECT PARKING BRAKE CABLE

    1. A293546

      Remove the 2 bolts and disconnect the parking brake cable.

  6. REMOVE NO. 1 FUEL TANK PROTECTOR

    1. A293548

      Remove the 2 clips and grommet.

    2. Remove the 2 bolts and fuel tank protector.

  7. DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

    1. A293550

      Slide the clamp and disconnect the No. 1 fuel evaporation tube sub-assembly.

  8. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A293551

      Disconnect the fuel tank main tube sub-assembly.

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  9. REMOVE FUEL HOSE PROTECTOR

    A199132

    1. Detach the claw and remove the fuel hose protector from the fuel tank to filler pipe hose.

  10. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

    1. A173328

      Loosen the hose clamp and disconnect the fuel tank to filler pipe hose from the fuel tank assembly.

  11. DISCONNECT CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY

    1. A293554

      Detach the hose clamp.

    2. A293552

      Slide the clamp and disconnect the charcoal canister outlet tube sub-assembly from the fuel tank breather tube.

  12. DISCONNECT NO. 3 FUEL TANK BREATHER TUBE SUB-ASSEMBLY

    1. A293553

      Disconnect the No. 3 fuel breather tube sub-assembly from the fuel tank assembly.

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  13. REMOVE FUEL TANK ASSEMBLY

    1. A293577

      Detach the 3 wire harness clamps.

    2. Using an engine lifter and attachments, support the fuel tank assembly.

    3. A293555

      Remove the 2 bolts and No. 1 fuel tank band sub-assembly.

    4. Remove the 2 bolts and No. 1 fuel tank band sub-assembly LH.

    5. Remove the 2 bolts and No. 2 fuel tank band sub-assembly.

    6. Slightly lower the engine lifter.

      Note:

      Be careful not to cut the wiring.

    7. A297843

      Disconnect the fuel pump connector and sender gauge connector.

      Note:

      • Before this procedure, check the connector for dirt, mud or other contamination.

      • Do not use any tools in this procedure.

    8. Detach the wire harness from the 3 clamps and remove the fuel tank assembly.

  14. DISCONNECT FUEL EMISSION HOSE

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  15. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

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  16. REMOVE FUEL TANK VENT TUBE SET PLATE

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  17. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP

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  18. REMOVE FUEL SENDER GAUGE ASSEMBLY

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  19. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    A299336

    1. Detach the 5 clamps and remove the fuel tank main tube sub-assembly.

  20. REMOVE NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

    1. Detach the 5 clamps and remove the No. 1 fuel evaporation tube sub-assembly.

  21. REMOVE NO. 3 FUEL TUBE CLAMP

    1. Remove the No. 3 fuel tube clamp from the fuel tank assembly.

  22. REMOVE NO. 5 FUEL TUBE CLAMP

    1. Remove the No. 5 fuel tube clamp from the fuel tank assembly.

  23. REMOVE FUEL TUBE GROMMET

    1. Remove the 3 fuel tube grommets from the fuel tank assembly.

  24. REMOVE CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY

    1. A293558

      Detach the 2 clamps and remove the canister outlet tube sub-assembly from the fuel tank assembly.

  25. REMOVE FUEL EMISSION HOSE

    1. A293559C01

      *1

      Retainer

      Pinch the retainer as shown in the illustration, and then remove the fuel emission hose.

      Note:

      • Clean off any dirt and foreign matter from the clip before disconnecting the hoses.

      • Do not use any tools in this procedure.

      • Do not forcefully bend or twist the nylon tube.

      • Put the hose in a plastic bag to prevent damage and contamination.

      • If the connector is stuck, pinch the retainer and push and pull the hose to disconnect it.