FUEL TANK(w/o Canister Pump Module) REMOVAL

PROCEDURE

  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. PRECAUTION

    Note:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work.

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  3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note:

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

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  4. REMOVE FRONT FLOOR COVER (w/ Cover)

    1. A332503

      Remove the bolt and nut.

    2. Detach the 5 clips and remove the front floor cover.

  5. REMOVE NO. 1 FUEL TANK PROTECTOR (w/ Cover)

    1. A373821

      Detach the 2 clips and remove the nut.

    2. A373822

      Loosen the clip and remove the No. 1 fuel tank protector.

  6. REMOVE NO. 1 FUEL TANK PROTECTOR (w/o Cover)

    1. A293548

      Remove the 2 clips and grommet.

    2. Remove the 2 bolts and fuel tank protector.

  7. REMOVE NO. 1 FLOOR UNDER COVER (w/ Cover)

    1. A373823

      Detach the clip and remove the 2 nuts and No. 1 floor under cover.

  8. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY

    1. A271433

      Remove the 2 bolts and disconnect the No. 2 parking brake cable assembly from the body.

  9. DISCONNECT NO. 1 FUEL EVAPORATION TUBE

    1. A313979

      Slide the hose clamp, and disconnect the No. 1 fuel evaporation tube from the fuel pipe.

  10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A313980

      Disconnect the fuel tank main tube sub-assembly from the fuel pipe.

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  11. REMOVE FUEL HOSE PROTECTOR

    1. A313981

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

  12. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

    1. A313982

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

  13. DISCONNECT CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY

    1. A313983

      Disconnect the clamp from the No. 2 fuel tank band.

    2. A310859

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

  14. REMOVE FUEL TANK ASSEMBLY

    1. A313985

      Disconnect the 3 wire harness clamps from the 2 No. 4 fuel tube clamps and the bracket on the vehicle side.

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

    3. A313986

      Remove the 2 bolts and No. 1 fuel tank band.

    4. Remove the 2 bolts and No. 2 fuel tank band.

    5. Slightly lower the engine lifter.

      Note:

      Be careful not to cut the wiring.

    6. A313984

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

    7. A313987

      Disconnect the fuel pump connector and fuel sender gauge assembly connector.

      Note:

      • Before starting the operation, check that there is no mud or other dirt on the connector.

      • Do not use any tools.

    8. Disconnect the 3 wire harness clamps from the 3 No. 4 fuel tube clamps.

  15. DISCONNECT FUEL EMISSION HOSE

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  16. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

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  17. REMOVE FUEL TANK VENT TUBE SET PLATE

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  18. REMOVE FUEL SUCTION TUBE ASSEMBLY

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  19. REMOVE FUEL SENDER GAUGE ASSEMBLY

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  20. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A314018C02

      *1

      Fuel Tank Main Tube Sub-assembly

      *2

      No. 1 Fuel Evaporation Tube Sub-assembly

      Disconnect the 5 clamps and remove the fuel tank main tube sub-assembly from the 5 No. 4 fuel tube clamps.

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

    1. Disconnect the 4 clamps and remove the No. 1 fuel evaporation tube sub-assembly from the 4 No. 4 fuel tube clamps.

  22. REMOVE CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY

    1. A314032

      Disconnect the 3 clamps and remove the charcoal canister outlet tube sub-assembly from the 3 No. 4 fuel tube clamps.

  23. REMOVE NO. 4 FUEL TUBE CLAMP

    1. A314017

      Remove the 8 No. 4 fuel tube clamps from the fuel tank assembly.

  24. REMOVE FUEL EVAPORATION TUBE SUB-ASSEMBLY

    1. A329282

      Remove the fuel evaporation tube sub-assembly from the fuel tank assembly.

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