Fuel Tank: Removal

(See PRECAUTION  )

(See REMOVAL )

1. Remove the 5 nuts and front floor heat insulator No.3.
   Fig 1: Locating Front Floor Heat Insulator N0.3 Nuts

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1. Disengage the 4 grommets.
2. Remove the screw and fuel tank protector sub-assembly No.1.
   Fig 2: Locating Fuel Tank Protector Sub-Assembly No.1 Grommets

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1. Remove the nut and disconnect the parking brake cable assembly No.3.
   Fig 3: Locating Parking Brake Cable Assembly No.3 Nut

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1. Separate the fuel tank wire connector from the bracket.
2. Disconnect the 2 connectors.
   Fig 4: Locating Fuel Tank Wire Connector And Bracket

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1. Disconnect the clamp from the charcoal canister protector.
2. Remove the 3 bolts and charcoal canister protector.
   Fig 5: Locating Charcoal Canister Protector Bolts And Clamp

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1. Disconnect the charcoal canister fuel hose from the charcoal canister assembly.
   1. Pinch the retainer and pull out the quick connector with the quick connector pushed to the pipe side to disconnect the charcoal canister fuel hose from the charcoal canister assembly.
      NOTE:

      • Remove dirt or foreign objects on the quick connector before this work.
      • Be careful not to allow foreign matter to scratch or come into contact with the pipe that is sealed by O-rings.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, kink, twist or turn the nylon tube.
      • Protect the connected part by covering it with a plastic bag after disconnecting the charcoal canister fuel hose.
      • If the quick connector and pipe are stuck, push and pull them to release.
        Fig 6: Disconnecting Charcoal Canister Fuel Hose

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1. Pinch the tabs of the retainer to disengage the lock claws and pull the retainer down as shown in the illustration.
2. Pull out the fuel tank main tube.
   NOTE:

   • Check for dirt or other foreign objects around the connector before this operation. Clean the connector as necessary.
   • Be careful not to allow mud or foreign matter to scratch or come into contact with the pipe and connector that are sealed by O-rings.
   • Do not use any tools for this operation.
   • Do not damage the disconnected pipe or connector. Prevent intrusion of foreign objects by covering the pipe and connector with a plastic bag.
   • When the pipe and connector are stuck, push and pull the connector to release. Pull out the connector carefully.
     Fig 7: Disconnecting Fuel Tank Main Tube Sub-Assembly

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1. Remove the checker of the breather lower tube connector.
2. Pinch the retainer of the breather lower tube connector, and pull out the breather lower tube connector to disconnect the breather lower tube from the fuel tank.
   NOTE:

   • Check for dirt around the connector before this operation. Remove the dirt as necessary.
   • Be careful not to allow mud or foreign matter to scratch or come into contact with the pipe and connector that are sealed by O-rings.
   • Do not use any tool in this operation.
   • Do not damage the disconnected pipe or connector. Prevent intrusion of foreign objects by covering the pipe and connector with a plastic bag.
   • When the pipe and the connector are stuck, push and pull the connector to release. Pull out the connector carefully.
     Fig 8: Disconnecting Breather Lower Tube

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1. Set a transmission jack to the fuel tank.
2. Remove the fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe.
   Fig 9: Locating Fuel Tube Connector

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3. Remove the 4 bolts and the fuel tank bands.
4. Operate the transmission jack, and disconnect the fuel inlet pipe.
5. Operate the transmission jack, and remove the fuel tank.
   Fig 10: Locating Fuel Tank Bands Bolts

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1. Disconnect the fuel pump connector.
2. Disconnect the clamp and vapor pressure sensor connector.
   Fig 11: Locating Fuel Pump Connector, Clamp And Vapor Pressure Sensor Connector

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3. Remove the tube joint clip and clamp, and pull out the fuel pump tube.
   NOTE:

   • Check for dirt around the fuel tube joint before this work. Clean the dirt away as necessary.
   • Be careful not to allow dirt or foreign matter to scratch or come into contact with the fuel tube connector and fuel suction plate that are sealed by O-rings.
   • Do not use any tools in this work.
   • Do not bend, kink or twist the nylon tube by force.
   • Cover the disconnected fuel tube joint with a plastic bag.
   • When the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube with the fingers, and turn it carefully to release. Disconnect the fuel tank tube.
     Fig 12: Pulling Out Fuel Pump Tube

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4. Remove the 8 bolts, fuel tank vent tube set plate and fuel pump connector plate.
   Fig 13: Locating Fuel Tank Vent Tube Set Plate And Fuel Pump Connector Plate Bolts

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5. Pull out the fuel pump assembly from the fuel tank.
   NOTE:

   • Do not damage the fuel pump filter.
   • Be careful not to bend the arm of the sender gauge.
6. Remove the gasket from the fuel suction tube.

1. Disconnect the connector and clamp.
   Fig 15: Locating Fuel Vapor Containment Valve Connector And Clamp

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2. Remove the 2 nuts from the fuel vapor containment valve.
   Fig 16: Locating Fuel Vapor Containment Valve Nuts

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3. Push the fuel tank vent hose deep into the fuel tank to release the lock pin.
4. Pinch portion A.
5. Pull out the fuel tank vent hose.
6. Remove the fuel vapor containment valve from the fuel tank.
   Fig 17: Pulling Out Fuel Tank Vent Hose

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1. Disconnect the 4 clamps and remove the fuel tank wire.
   Fig 18: Locating Fuel Tank Wire Clamps

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1. Remove the fuel tank main tube from the clamp.
   Fig 19: Locating Fuel Tank Main Tube Clamp

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1. Remove the 2 clamps of the fuel tank main tube from the fuel tank.
   Fig 20: Locating Clamps Of Fuel Tank Main Tube

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2. Remove the clamp from the fuel tank.
   Fig 21: Locating Fuel Tank Clamp

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1. Remove the 8 fuel tank cushions from the fuel tank.
   Fig 22: Identifying Fuel Tank Cushions

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