GSIC - Global Service Information Center

# FUEL TANK > REMOVAL

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1. DISCONNECT CABLE FROM 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. LOOSEN FUEL TANK CAP

3. REMOVE NO. 1 FUEL TANK PROTECTOR

1. Remove the 4 nuts and fuel tank protector.

4. DISCONNECT FUEL MAIN TUBE AND FUEL RETURN TUBE

1. Move the 2 clamps to remove the 2 tubes.

   NOTICE:
   1. To protect the tube, cover it with a plastic bag after checking it.
   2. If the tube and pipe are stuck, turn the tube carefully to free it and then disconnect the fuel tank tube.

5. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

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

6. DISCONNECT FUEL TANK BREATHER HOSE

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

7. REMOVE FUEL TANK FILLER PIPE

1. Remove the bolt and filler pipe.

8. REMOVE FUEL TANK

1. Set a mission jack to the fuel tank.

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

1. Slightly lower the mission jack.

   NOTICE:
     Be careful not to cut the wirings.

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

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

   NOTICE:
   1. Before this procedure, check the connector for dirt, mud or other contamination.
   2. Do not use any tools in this procedure.

9. REMOVE NO. 1 FUEL TANK CUSHION

1. Remove the nut.

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

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

10. REMOVE FUEL PUMP GAUGE RETAINER

1. Remove the 2 tube joint clips and pull out the 2 fuel pump tubes.

   NOTICE:

   1. Before beginning this procedure, check for foreign matter in the fuel suction tube. Clean if necessary.
   2. Keep the O-ring free of foreign matter, as it becomes contaminated easily.
   3. Do not use any tools in this procedure.
   4. Do not forcefully bend or twist the tube.
   5. Put the tube in a plastic bag to prevent damage and contamination.
   6. Protect the fuel suction tube's joint with tape or equivalent to prevent contamination from foreign matter.
   7. If the fuel suction tube and tube are stuck together, pinch the tube and turn it carefully to disconnect it.

1. Using SST, loosen the retainer.

   SST
     09808-14020 (09808-01410, 09808-01420, 09808-01430)

   HINT:
     Fit the tips of SST onto the ribs of the retainer.

   NOTICE:
   1. When the retainer is loosened, be careful as the fuel pump will spring upward from the force of the spring.
   2. Clean the fuel suction tube before removing it.

1. Remove the retainer.

11. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

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

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

1. Remove the gasket from the fuel tank.