FUEL TANK REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:


    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.

    • Even after discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment.


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

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

    2. A01E23AE01

      Disconnect the fuel pump connector.

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

    4. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.

      Tech Tips

      DTC P0171/25 (system too lean) may be set.

    5. Crank the engine again, then check that the engine does not start.

    6. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.

    7. Connect the fuel pump connector.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait for 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  3. REMOVE FUEL TANK CAP

  4. REMOVE NO. 3 FUEL TUBE CLAMP


    1. A01E2K0E01

      Remove the tube clamp from the fuel tube.

  5. DISCONNECT FUEL MAIN TUBE AND FUEL RETURN TUBE


    1. A01E1A1E02

      Pinch and pull the main tube connector to disconnect the connector from the pipe. Then pinch and pull the return tube connector to disconnect the connector from the pipe.

      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.

    2. Disconnect the EVAP hose.

  6. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01E1UBE01

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

  7. DISCONNECT FUEL TANK BREATHER HOSE


    1. Disconnect the breather hose from the fuel tank filler pipe.

  8. REMOVE FUEL TANK FILLER PIPE


    1. Remove the bolt and filler pipe.

  9. REMOVE FUEL TANK


    1. A01DYUBE01

      Set a mission jack to the fuel tank.

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

    3. Slightly lower the mission jack.

      Note

      Be careful not to cut the wirings.

    4. A01DZHSE01

      Remove the clip. Then fold back approximately half of each cushion rubber so that the wire harness can be removed in the next step.

    5. A01DWSGE01

      Disconnect the fuel pump connector and detach the 6 wire harness clips from the fuel tank.

      Note


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

      • Do not use any tools in this procedure.

  10. REMOVE NO. 1 FUEL TANK CUSHION


    1. A01E302E03

      Using needle-nose pliers, remove the 4 clips and nut as shown in the illustration and then remove the heat insulator.

    2. A01DXWGE01

      Remove the clip and 2 fuel tank cushions from the fuel tank.

  11. REMOVE FUEL PUMP GAUGE RETAINER


    1. A01DUZQE02

      Remove the 2 tube joint clips and pull out the 2 fuel tank 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. Remove the fuel tank return tube and fuel tank main tube from the fuel tank.

    3. A01DZK5E03

      Temporarily install SST (plate and 4 claws) to the fuel pump gauge retainer.

      SST
      09808-14030

      Tech Tips


      • Be sure to use 4 SST (claws) as shown in the illustration.

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

    4. While pressing SST (claws) against the fuel pump gauge retainer ribs securely, install the 4 bolts.

      Tech Tips

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

    5. Install SST (handle).

    6. A01E18CE02

      Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing SST, rotate the handle slowly to loosen the fuel pump gauge retainer.

      SST
      09808-14030

      Note


      • When the retainer is loosened, be careful as the fuel pump will spring upward from the force of the spring.

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

      • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.

      • Make sure to rotate SST (handle) horizontally. If SST (handle) is rotated at an angle, SST may come off.

      • Do not spin SST too fast or use an impact wrench as this may result in damage to components.

      • If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.

      Tech Tips

      The tips of SST (claws) can be fitted onto the ribs of the fuel pump gauge retainer.

    7. Remove the fuel pump gauge retainer.

  12. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


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

      Note

      Be careful not to bend the arm of the fuel sender gauge.

    2. Remove the gasket from the fuel tank.