FUEL TANK REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

    Click here

  4. REMOVE REAR NO. 2 FLOOR SERVICE HOLE COVER


    1. A01EKZO

      Remove the rear No. 2 floor service hole cover.

    2. Disconnect the fuel sender gauge connector.

  5. REMOVE FUEL SENDER GAUGE ASSEMBLY


    1. A01EJWP

      Remove the 6 bolts and fuel sender gauge assembly from the fuel tank.

      Note

      Be careful not to bend the arm of the fuel sender gauge.

  6. DRAIN FUEL

  7. REMOVE CENTER EXHAUST PIPE ASSEMBLY

    Click here

  8. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

    Click here

  9. REMOVE ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY (for AWD)


    1. A01EMPL

      Remove the 4 bolts.

    2. Using a plastic hammer, lightly tap the electro magnetic control coupling sub-assembly to remove it from the rear differential carrier assembly.

      Note

      Do not damage the contact surface.

  10. REMOVE FRONT FLOOR BRACE LH


    1. A01ELEME01
      Text in Illustration
      *1 Front Floor Brace LH
      *2 Front Floor Brace RH

      Remove the bolt, 2 nuts and front floor brace LH.

  11. REMOVE FRONT FLOOR BRACE RH


    1. Remove the bolt, 2 nuts and front floor brace RH.

  12. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. A01EL53

      Remove the 4 bolts and No. 1 fuel tank protector sub-assembly.

  13. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. A01EM47

      Remove the bolt and nut and separate the No. 2 parking brake cable assembly.

  14. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. A01EMCI

      Remove the bolt and nut and separate the No. 3 parking brake cable assembly.

  15. REMOVE FUEL TANK ASSEMBLY


    1. A01EL1EE01
      Text in Illustration
      *a Retainer
      *b Fuel Pipe
      *c Fuel Tube Connector
      *d O-ring
      *e Claw
      A01EM1I Push
      A01EMIT Pull out
      A01EKKE 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


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

        • 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 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.

      3. Check if there is any 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.

    2. A01EJ41E01
      Text in Illustration
      *a Retainer
      *b Claw
      A01EM1I Pinch
      A01EMIT Pull
      A01EKKE Pull off

      Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tank vent hose sub-assembly from the charcoal canister assembly.

      Note


      • Remove any dirt or foreign matter on the fuel tank vent hose sub-assembly before performing this work.

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

      • Be sure to disconnect the fuel tank vent hose sub-assembly by hand.

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

      • Protect the disconnected parts by covering them with plastic bags after disconnecting the fuel tank vent hose sub-assembly.

      • If the fuel tank vent hose sub-assembly and charcoal canister assembly are stuck, push and pull on them to release.

      Tech Tips

      Do not remove the retainer.

    3. A01ELZ5

      Disengage the 2 clamps to disconnect the fuel tank vent hose sub-assembly.

    4. A01EM8IE01
      Text in Illustration
      *a Retainer
      *b O-ring
      *c Fuel Tube Connector
      *d Fuel Pipe
      A01EM1I Pull out
      A01EMIT Pull off

      Disconnect the fuel tank breather tube sub-assembly.


      1. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

        Note


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

        • 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 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.

      3. Check if there is any 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.

    5. A01EMRP

      Loosen the clamp, then disconnect the fuel tank to filter pipe hose.

    6. A01EMFM

      Support the fuel tank assembly using an engine lifter.

    7. A01ELU1

      Remove the 2 set bolts of the fuel tank band sub-assemblies.

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

      Note


      • Do not 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.

    9. A01EMDM

      Remove the 2 straight pins and 2 fuel tank band sub-assemblies as shown in the illustration.

    10. A01ELPI

      Remove the 4 clip nuts from the fuel tank assembly.

  16. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY


    1. A01EM3HE01
      Text in Illustration
      *a Retainer
      *b Claw
      A01EM1I Pinch
      A01EMIT Pull
      A01EKKE Pull off

      Disengage the 2 claws of the retainer. Pull out the retainer and remove the fuel tank vent hose sub-assembly from the fuel tank assembly.

      Note


      • Remove any dirt or foreign matter on the fuel tank vent hose sub-assembly before performing this work.

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

      • Be sure to disconnect the fuel tank vent hose sub-assembly by hand.

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

      • Protect the disconnected parts by covering them with plastic bags after disconnecting the fuel tank vent hose sub-assembly.

      • If the fuel tank vent hose sub-assembly and fuel tank assembly are stuck, push and pull on them to release.

      Tech Tips

      Do not remove the retainer.

  17. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY


    1. A01EK8PE01
      Text in Illustration
      *a Retainer
      *b O-ring
      *c Fuel Tube Connector
      *d Fuel Pipe
      A01EM1I Pull out
      A01EMIT Pull off

      Remove the fuel tank breather tube sub-assembly from the fuel tank assembly.


      1. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

        Note


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

        • 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 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.

      3. Check if there is any 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.

  18. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A01EMGE

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

  19. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01EK28

      Remove the fuel tank main tube sub-assembly from the fuel main tube support.

  20. REMOVE FUEL MAIN TUBE SUPPORT


    1. A01EJQZ

      Remove the bolt and fuel main tube support from the fuel tank assembly.

  21. REMOVE NO. 1 FUEL TANK CUSHION


    1. A01EMJ3

      Remove the 8 No. 1 fuel tank cushions from the fuel tank assembly.