FUEL TANK > REMOVAL

for Preparation Click here

NOTICE:

1. Perform the following procedures to prevent fuel from spilling out before removing any fuel system parts.
   

1. Pressure will still remain in the fuel line even after performing the following procedures. When disconnecting the fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying.
   

1. Remove the F/PMP fuse.
   
   

   1. Remove the engine room No. 2 relay block cover upper.
      

   2. Remove the F/PMP fuse.
      

   3. Start the engine.
      

   4. After the engine has stopped, turn the engine switch off.
      

      HINT:

      DTC P0171/25 (fuel problem) and/or P0191/49 (fuel pressure sensor signal error) may be detected.

   5. Crank the engine again. Check that the engine does not start.
      

   6. Remove the fuel tank cap to discharge pressure from the fuel tank.
      

   7. Reinstall the F/PMP fuse.
      

2. Disconnect the fuel pump connector.
   
   

   1. Remove the rear seat cushion.
      

   2. Remove the rear floor service hole cover.
      

   3. Disconnect the fuel pump connector.
      

   4. Start the engine.
      

   5. After the engine has stopped, turn the engine switch off.
      

      HINT:

      DTC P0171/25 (fuel problem) and/or P0191/49 (fuel pressure sensor signal error) may be detected.

   6. Crank the engine again. Check that the engine does not start.
      

   7. Remove the fuel tank cap to discharge pressure from the fuel tank.
      

   8. Reconnect the fuel pump connector.
      

   9. Install the rear floor service hole cover.
      

   10. Install the rear seat.
       

CAUTION:

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

1. Detach the seat cushion's 2 front hooks from the vehicle body.
   

   NOTICE:

   Follow the instructions below carefully as the cushion frame deforms easily.

   
   

   1. Choose a hook to detach first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to detach the hook.
      

   2. Repeat for the other hook.
      

2. Detach the seat cushion's 2 rear hooks from the seatback.
   

3. Remove the seat cushion.
   

1. Remove the clip and room partition pad.
   

1. Remove the service hole cover and disconnect the fuel pump connector.
   

1. Disconnect the fuel tank main tube and pump tube.
   
   

   
   
   

   1. Remove the 2 tube joint clips and fuel tubes.
      

      NOTICE:

      1. Remove any dirt and foreign matter on the fuel tube joint before performing this work.
         
      1. 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.
         
      1. Perform this work by hand. Do not use any tools.
         
      1. Do not forcibly bend, twist or turn the nylon tube.
         
      1. Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
         

2. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
   

   SST

   09808-14020  
   

   NOTICE:

   Do not use any other tools such as a screwdriver.

   HINT:

   Fit the tips of SST on the ribs of the retainer.

3. While holding the fuel suction tube by hand, remove the fuel pump gauge retainer.
   

4. Disconnect the fuel suction tube.
   

5. Remove the fuel suction tube from the fuel tank.
   

   NOTICE:

   1. Make sure that the sender gauge arm does not bend.
      
   1. Do not damage the fuel suction tube.
      

1. Remove the service hole cover and disconnect the fuel sender gauge connector.
   

1. Disconnect the fuel pump tube.
   
   

   
   
   

   1. Remove the tube joint clip and fuel pump tube.
      

      NOTICE:

      1. Remove any dirt and foreign matter on the fuel tube joint before performing this work.
         
      1. 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.
         
      1. Perform this work by hand. Do not use any tools.
         
      1. Do not forcibly bend, twist or turn the nylon tube.
         
      1. Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
         

2. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
   

   SST

   09808-14020  
   

   NOTICE:

   Do not use any other tools such as a screwdriver.

   HINT:

   Fit the tips of SST on the ribs of the retainer.

3. While holding the SST with one hand, remove the fuel pump gauge retainer.
   

4. Remove the fuel return vent tube from the fuel tank.
   

   NOTICE:

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

5. Remove the No. 1 fuel suction tube set gasket from the fuel tank.
   

6. Disconnect the fuel sender gauge connector.
   

7. Press down on the sender gauge claw labeled A. Then slide the sender gauge upward.
   

1. Remove the exhaust pipe (Click here).
   

1. Remove the 3 nuts, 2 clips and floor cover.
   

1. Remove the 3 nuts and heat insulator.
   

1. Using SST, loosen the adjusting nut until it can be turned by hand.
   

   SST

   09922-10010  
   

   HINT:

   Use 2 same type of SST.

2. Put matchmarks on the transmission companion flange, flexible coupling and intermediate shaft.
   

3. Remove the 3 bolts, 3 washers and 3 nuts.
   

   NOTICE:

   The propeller shaft and flexible coupling should not be separated.

4. Put matchmarks on the differential companion flange, flexible coupling and propeller shaft.
   

5. Remove the 3 bolts, 3 washers and 3 nuts.
   

   NOTICE:

   The propeller shaft and flexible coupling should not be separated.

6. Remove the 2 bolts and 2 center support bearing washers.
   

   HINT:

   Some vehicles are not equipped with the center support bearing washers.

7. Push the rear propeller shaft straight forward to compress the propeller shaft and pull out the propeller shaft from the centering pin of the differential.
   

   NOTICE:

   Press the propeller shaft straight ahead to keep the transmission and intermediate shaft aligned straight.

   HINT:

   If it is difficult to separate the flange from the flexible coupling, pry it using a screwdriver.

8. Pull the propeller shaft outward from the vehicle's rear.
   

   NOTICE:

   The intermediate shaft and propeller shaft should not be separated.

1. Remove the 4 nuts and fuel tank protector.
   

1. Remove the 4 nuts and differential support protector.
   

1. Remove the 4 nuts and differential support protector.
   

1. Remove the 3 bolts and member cover.
   

1. Remove the 3 bolts and member cover.
   

1. Remove the 4 bolts and suspension member brace.
   

1. Remove the 4 bolts and suspension member brace.
   

1. Remove the 2 parking brake cables from the 4 clamps.
   

2. Remove the 4 bolts and disconnect the 2 parking brake cables.
   

NOTICE:

1. Check for any dirt or 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.
   

1. Do not use any tools to separate the pipe and connector.
   

1. Do not forcefully bend or twist the nylon tube.
   

1. Check for any dirt or foreign matter on the pipe seal surface. Clean if necessary.
   

1. Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
   

1. If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
   

1. Pinch and pull the main tube connector to disconnect the connector from the pipe.
   

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

1. Remove the bracket.
   

2. Disconnect the 2 fuel emission hoses.
   

1. Remove the 2 nuts from the fuel tank.
   

2. Place a mission jack under the fuel tank.
   

3. Remove the 4 nuts and 2 fuel tank bands.
   

1. Remove the 4 clamps, fuel pump tube and fuel tank main tube.
   

1. Remove the tank cushions and fuel tank brackets.
   

1. Remove the 2 nuts and fuel tank protector.