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. SEPARATE 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 separate the No. 2 parking brake cable assembly.

  7. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. Remove the nut and separate 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 from the fuel tank sub-assembly.

  10. 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. A01W14WE02
      Text in Illustration
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B001O8N Push
      B001OAO Pull out
      B001NW5 Pull off

      Disconnect the fuel tank main tube sub-assembly.


      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.

  11. DISCONNECT FUEL EMISSION HOSE


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

      Slide the clip and disconnect the fuel emission hose.

  12. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. Slide 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

    Note

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


    1. A01W40HE02
      Text in Illustration
      *a Retainer
      B001O8N Pull out
      B001OAO Pull off

      Pull out the retainer to disengage the lock claws and pull off the fuel tank to filler pipe hose from the fuel tank sub-assembly.

      Note


      • Do not scratch or allow any 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.

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

      • Do not bend, twist, pinch or kink 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.

      Tech Tips

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

    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.

      • Be careful not to drop the fuel tank sub-assembly.

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

  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01W0KZ

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

  17. REMOVE CHARCOAL CANISTER OUTLET HOSE


    1. A01W423

      Disengage the No. 2 fuel tube clamp to remove the charcoal canister outlet hose from the fuel tank sub-assembly.

  18. REMOVE NO. 1 FUEL TUBE CLAMP


    1. A01W1T0

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

  19. REMOVE FUEL TANK BREATHER HOSE


    1. A01W0W9

      Loosen the clamp, then remove the fuel tank breather hose from the fuel tank sub-assembly.

  20. REMOVE NO. 1 FUEL TANK CUSHION


    1. A01W077

      Remove the 5 No. 1 fuel tank cushions from the fuel tank sub-assembly.