FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

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  3. DRAIN FUEL

  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    Note

    Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


    1. B008GHJC01
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B008GAS Push
      B008GGT Pull out
      B008GIB Pull off

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


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

        • Do not bend, twist, pinch or kink the nylon tube.

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  6. DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

    Note

    Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


    1. B008GE3C01
      *a Retainer
      *b Fuel Tube Connector
      *c O-ring
      *d Fuel Pipe
      *e Claw
      B008GAS Push
      B008GGT Pull out
      B008GIB Pull off

      Remove the No. 1 fuel evaporation tube sub-assembly from the fuel pipe.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe (fuel pipe).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  7. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B008GI3

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

  8. DISCONNECT FUEL TANK BREATHER TUBE


    1. B008GDF

      Loosen the clamp and disconnect the fuel tank breather tube from the fuel tank breather tube connector.

    2. B008GBYC01
      *1 Breather Tube Clamp
      *2 No. 2 Evaporation Vent Tube Clamp

      Disengage the 2 clamps to disconnect the fuel tank breather tube from the breather tube clamp and No. 2 evaporation vent tube clamp.

  9. DISCONNECT CHARCOAL CANISTER OUTLET HOSE


    1. B008GGA

      Disconnect the charcoal canister outlet hose from the No. 6 fuel tank breather tube.

  10. SEPARATE PARKING BRAKE CABLE ASSEMBLY


    1. B008GAQC02
      B008GAS Bolt
      B008GGT Nut

      Disengage the 4 clamps.

    2. Remove the 2 bolts and 2 nuts, and separate the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly.

  11. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

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  12. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

    Click here

  13. REMOVE FUEL TANK ASSEMBLY


    1. B008GGPC03
      B008GAS Bolt
      B008GGT Nut

      Support the fuel tank assembly using an engine lifter.

      Tech Tips

      Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

    2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank band sub-assemblies.

    3. Lower the engine lifter to remove the fuel tank assembly.

      Note


      • Slowly operate the engine lifter to lower the fuel tank assembly.

      • Be careful not to drop the fuel tank assembly.

      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

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


    1. B008GDP

      Remove the No. 1 fuel evaporation tube sub-assembly from the fuel tank assembly.

  15. REMOVE CHARCOAL CANISTER OUTLET HOSE


    1. B008GD0

      Disengage the clamp to remove the charcoal canister outlet hose from the fuel tank assembly.

    2. B008GEJ

      Disengage the clamp to remove the No. 4 fuel tube clamp from the fuel tank assembly.

  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B008GFR

      Disengage the 3 clamps to remove the fuel tank main tube sub-assembly from the fuel tank assembly.

    2. B008GGUC02
      *1 No. 3 Fuel Tube Clamp
      *2 No. 5 Fuel Tube Clamp

      Disengage the 2 clamps to remove the No. 3 fuel tube clamp and No. 5 fuel tube clamp from the fuel tank assembly.

  17. REMOVE FUEL TANK CUSHION


    1. B008GEU

      Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly.

    2. B008GATC03
      *1 Fuel Tank Bracket
      *2 Fuel Tank Cushion
      *3 Fuel Tank Cushion Set
      *a RH side
      *b LH side

      Remove the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set from the fuel tank assembly.

  18. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. B008GCGC03
      *1 No. 1 Fuel Tank Protector Sub-assembly
      *2 No. 2 Fuel Tank Protector
      *3 No. 3 Fuel Tank Protector

      Remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.

    2. Remove the No. 2 fuel tank protector and No. 3 fuel tank protector from the fuel tank assembly.