FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  2. DRAIN FUEL

  3. REMOVE CENTER EXHAUST PIPE ASSEMBLY

    Click here

  4. REMOVE NO. 1 FLOOR UNDER COVER

    Click here

  5. REMOVE NO. 2 FLOOR UNDER COVER

    Click here

  6. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. A01W38PE01
      Text in Illustration
      *1 No. 2 Parking Brake Cable Assembly
      *2 No. 3 Parking Brake Cable Assembly

      Remove the nut and disconnect the No. 2 parking brake cable assembly.

  7. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. Remove the nut and disconnect the No. 3 parking brake cable assembly.

  8. REMOVE REAR NO. 1 STABILIZER BAR BRACKET


    1. A01W16L

      Remove the 4 nuts and 2 rear No. 1 stabilizer bar brackets.

  9. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A01W1XO

      Remove the 3 clips and No. 1 fuel tank protector.

  10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01W18OE01
      Text in Illustration
      *1 Retainer
      *2 Tab
      *3 Fuel Tube Connector
      *4 Fuel Pipe
      *5 O-ring
      B001O8N Pinch
      B001OAO Pull

      Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration.

    2. Pull out the fuel tank main tube sub-assembly.

      Note


      • Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before performing this work.

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

      • Only disconnect the fuel tube connector by hand.

      • Do not forcibly bend, twist or turn the fuel tank main tube sub-assembly.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

  11. DISCONNECT FUEL EMISSION HOSE


    1. A01W1TBE01
      Text in Illustration
      *1 Fuel Emission Hose
      *2 No. 1 Charcoal Canister Outlet Hose

      Loosen the clip and disconnect the fuel emission hose.

  12. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. Loosen the clip and disconnect the No. 1 charcoal canister outlet hose.

  13. DISCONNECT FUEL TANK BREATHER HOSE


    1. A01W5HF

      Loosen the clamp, then disconnect the fuel tank breather hose.

  14. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01W3AJE01
      Text in Illustration
      *1 Retainer
      B001O8N Pull
      B001OAO Pull out

      Pull the tab of the retainer to disengage the lock claws and pull out the fuel tank to filler pipe hose.

      Note


      • Remove any dirt or foreign matter on the fuel tank to filler pipe hose connector before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank to filler pipe hose connector has an O-ring that seals the fuel tank sub-assembly.

      • Only disconnect the fuel tank to filler pipe hose connector by hand.

      • Do not forcibly bend, twist or turn the fuel tank to filler pipe hose.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank to filler pipe hose.

      • If the fuel tank to filler pipe hose connector and fuel tank sub-assembly are stuck, push and pull to release them.

  15. REMOVE FUEL TANK SUB-ASSEMBLY


    1. A01VZB4

      Support the fuel tank sub-assembly using an engine lifter.

    2. A01VZQW

      Remove the 4 bolts of the 2 fuel tank bands.

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

      Note


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

      • Do not drop the fuel tank sub-assembly.

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

  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01W533

      Disconnect the No. 1 fuel tube clamp and remove the fuel tank main tube sub-assembly.

  17. DISCONNECT NO. 2 FUEL TUBE CLAMP


    1. A01W423

      Disconnect the No. 2 fuel tube clamp and remove the charcoal canister outlet hose.

  18. REMOVE NO. 1 FUEL TUBE CLAMP


    1. A01W1T0

      Remove the No. 1 fuel tube clamp.

  19. REMOVE FUEL TANK BREATHER HOSE


    1. A01W4DK

      Loosen the clamp, then remove the fuel tank breather hose.

  20. REMOVE NO. 1 FUEL TANK CUSHION


    1. A01W20O

      Remove the 5 No. 1 fuel tank cushions.