FUEL TANK REMOVAL

PROCEDURE


  1. PRECAUTION


    1. A0048Z0C09
      *a 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 TANK CAP ASSEMBLY

  3. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  4. DRAIN FUEL

  5. REMOVE FRONT NO. 4 FLOOR HEAT INSULATOR


    1. A0049C8

      Remove the 2 nuts and front No. 4 floor heat insulator from the vehicle.

  6. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A0048ZD

      Remove the clip.

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

  7. 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. A00485NC05
      *a Fuel Tube Connector Cover
      *b Fuel Tube Connector
      *c O-ring
      *d Retainer
      A0049LZ Pinch
      A004864 Pull

      Release the lock of the fuel tube connector cover as shown in the illustration, then pull out the fuel tank main tube sub-assembly.

      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.

  8. DISCONNECT NO. 2 FUEL EMISSION TUBE


    1. A004819

      Slide the hose clip and disconnect the No. 2 fuel emission tube from the fuel tank to canister tube.

  9. REMOVE FUEL TANK ASSEMBLY

    A00494R

    1. Remove the bolt.

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

    3. A004A4Z

      Remove the 4 bolts, fuel tank side plate and fuel tank assembly from the vehicle.

      Note

      Make sure that the fuel tank assembly does not fall.

  10. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A004AH0

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

  11. REMOVE NO. 2 FUEL EMISSION TUBE


    1. A004A6K

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

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


    1. A0047OJC01
      *1 No. 6 Fuel Tank Breather Tube

      Disconnect the No. 1 canister outlet hose sub-assembly from the No. 6 fuel tank breather tube.

    2. Disengage the clamp to remove the No. 1 canister outlet hose sub-assembly from the fuel tank assembly.