FUEL TANK(for TMC Made) REMOVAL

PROCEDURE


  1. PRECAUTION


    1. A01VG0BE01
      Text in Illustration
      *1 Cord

      When removing and storing the fuel tank assembly, arrange the inlet hose as shown in the illustration, and secure the fuel tank assembly using a cord or similar.

      Note

      Depending on the arrangement of the inlet hose during storage, the inlet hose and rear suspension may interfere and cause fuel leakage.

  2. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

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  3. DRAIN FUEL

  4. REMOVE FRONT NO. 2 FLOOR HEAT INSULATOR


    1. A01VJT2

      Remove the 2 nuts and the front No. 2 floor heat insulator.

  5. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A01VGPS

      Remove the clip.

    2. Remove the bolt and fuel tank cover vent case sub-assembly.

  6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    Note

    Before disconnecting the fuel tube connector, check for dirt or other foreign matter on the fuel tube connector and the pipe, and clean them if necessary.


    1. A01VIKUE01
      Text in Illustration
      *1 Checker
      *2 Fuel Tube Connector
      *3 O-ring
      *4 Retainer
      A01VL3H Pinch
      A01VE7C Pull

      Disengage the fuel tube connector cover.

    2. Squeeze the retainer by hand from both sides, and pull out the fuel tube connector from the pipe.

      Note


      • If the fuel tube connector and pipe are stuck together, push in and pull out the fuel tube connector while squeezing the pipe to release the connection, and then disconnect the fuel tube connector.

      • Clean away any dirt or foreign matter from the fuel tube connector before performing the operation.

      • The fuel tube connector and pipe are sealed by O-rings, so be careful to prevent damage to and foreign matter sticking to the contact surfaces.

      • Do not use any tools.

      • After disconnecting the fuel tube connector, check that there is no foreign matter on the seal surface of the pipe.

      • After disconnecting the fuel tube, protect the contact surfaces by covering them with a plastic bag.

      • Do not bend or twist the tubes.

  7. DISCONNECT NO. 2 FUEL EMISSION TUBE

    Note

    Before disconnecting the fuel tube connector, check for dirt or other foreign matter on the fuel tube connector and the pipe, and clean them if necessary.


    1. A01VJJFE02
      Text in Illustration
      *1 Nylon Tube
      *2 O-ring
      *3 Fuel Pipe
      *4 Retainer
      *a Pull Back
      *b Pull Out

      Loosen the clamp and disconnect the No. 2 fuel emission tube.

      Note


      • If the fuel tube connector and pipe are stuck together, push in and pull out the fuel tube connector while squeezing the pipe to release the connection, and then disconnect the fuel tube connector.

      • Clean away any dirt or foreign matter from the fuel tube connector before performing the operation.

      • The fuel tube connector and pipe are sealed by O-ring, so be careful to prevent damage to and foreign matter sticking to the contact surfaces.

      • Do not use any tools.

      • After disconnecting the fuel tube connector, check that there is no foreign matter on the seal surface of the pipe.

      • After disconnecting the fuel tube, protect the contact surfaces by covering them with a plastic bag.

      • Do not bend or twist the tubes.

  8. REMOVE FUEL TANK ASSEMBLY

    A01VJZY

    1. Disengage the clip as shown in the illustration and remove the fuel tank filler pipe flange plate.

    2. Using an engine lifter, support the fuel tank assembly.

    3. A01VIJ2

      Separate the 2 fuel hoses shown in the illustration.

    4. A01VFU4

      Remove the 4 bolts and fuel tank assembly.

      Note

      Make sure that the fuel tank does not fall.

  9. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01VF8C

      Disengage the clamp and remove the fuel tank main tube from the fuel tank assembly.

  10. REMOVE NO. 2 FUEL EMISSION TUBE


    1. A01VIN8

      Disengage the clamp and remove the No. 2 fuel emission tube from the fuel tank assembly.

  11. REMOVE NO. 1 CANISTER OUTLET HOSE SUB-ASSEMBLY


    1. A01VKEL

      Disengage the clamp and remove the No. 1 canister outlet hose from the fuel tank assembly.

  12. REMOVE FUEL HOSE CLAMP


    1. A01VLTJ

      Remove the fuel hose clamp.

  13. REMOVE NO. 2 FUEL TANK FILLER PIPE SUPPORT


    1. A01VLFA

      Disengage the clamp as shown in the illustration, and remove the No. 2 fuel tank filler pipe support.

  14. REMOVE NO. 1 FUEL TANK FILLER PIPE SUPPORT


    1. A01VHHR

      Disengage the clamp as shown in the illustration, and remove the No. 1 fuel tank filler pipe support.

  15. REMOVE NO. 3 FUEL TANK FILLER PIPE SUPPORT


    1. A01VLKV

      Disengage the clamp as shown in the illustration, and remove the No. 3 fuel tank filler pipe support.