FUEL TANK(w/o Canister Pump Module) REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

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  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

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  3. DRAIN FUEL

  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  5. DISCONNECT FUEL TUBE


    1. A000SM7E03
      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 Nylon Tube
      *4 O-Ring
      *5 Pipe

      Detach the 2 claws of the fuel tube connector retainer, push down the retainer and disconnect the fuel tank main tube sub-assembly and fuel tank return tube as shown in the illustration.

      Note


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

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

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, twist or turn the nylon tube.

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

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

    2. A000PYAE04
      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 O-Ring
      *4 Pipe

      Detach the 2 claws of the fuel tube connector retainer, and then pull the retainer to disconnect the No. 1 fuel evaporation tube sub-assembly as shown in the illustration.

      Note


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

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

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, twist or turn the nylon tube.

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

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

  6. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A000RUR

      Loosen the hose clamp and disconnect the fuel tank to filler pipe hose.

  7. DISCONNECT FUEL TANK BREATHER TUBE


    1. A000O7Z

      Loosen the hose clamp and disconnect the fuel tank breather tube from the fuel tank filler pipe sub-assembly.

    2. A000N9S

      Disconnect the fuel tank breather tube from the 2 hose clamps.

  8. DISCONNECT CHARCOAL CANISTER OUTLET HOSE


    1. A000R9N

      Disconnect the charcoal canister outlet hose from the fuel tank filler pipe sub-assembly.

  9. REMOVE REAR SUSPENSION MEMBER BRACE

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  10. REMOVE FUEL TANK ASSEMBLY


    1. A000QFG

      Using an engine lifter and attachments, support the fuel tank assembly.

      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

    2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank bands.

    3. Using an engine lifter, lower the fuel tank assembly and remove it.

  11. REMOVE NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A000R7N

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

  12. REMOVE CHARCOAL CANISTER OUTLET HOSE


    1. A000SM9

      Remove the charcoal canister outlet hose and No. 4 fuel tube clamp from the fuel tank assembly.

  13. REMOVE FUEL TUBE


    1. A000MX7E03
      Text in Illustration
      *1 Fuel Tank Return Tube
      *2 Fuel Tank Main Tube Sub-assembly

      Detach the clamp and remove the fuel tank return tube and fuel tank main tube sub-assembly from the fuel tank assembly.

    2. Remove the No. 5 fuel tube clamp from the fuel tank assembly.

  14. REMOVE FUEL TANK CUSHION


    1. A000QSL

      Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly.

    2. A000SZAE01
      Text in Illustration
      *1 Fuel Tank Bracket
      *2 Fuel Tank Cushion
      *3 Fuel Tank Cushion Set
      *a RH side
      *b LH side

      Remove the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set from the fuel tank assembly.

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


    1. A000SUQE01
      Text in Illustration
      *1 No. 1 Fuel Tank Protector Sub-assembly
      *2 No. 2 Fuel Tank Protector
      *3 No. 3 Fuel Tank Protector

      Remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.

    2. Remove the No. 2 fuel tank protector and No. 3 fuel tank protector from the fuel tank assembly.