FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY (for Sedan)

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  2. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY (except Sedan)

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  3. DRAIN FUEL

  4. REMOVE REAR FLOOR SIDE MEMBER COVER LH (w/ Cover)

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  5. REMOVE REAR FLOOR SIDE MEMBER COVER RH (w/ Cover)

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  6. REMOVE REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY

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  7. REMOVE REAR NO. 1 FLOOR UNDER COVER


    1. B0043MJC01
      B0042CO Grommet
      B0043VS Nut

      Remove the 4 clips and nut.

    2. Loosen the 2 grommets, then remove the rear No. 1 floor under cover.

  8. REMOVE CENTER EXHAUST PIPE ASSEMBLY

    Click here

  9. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. B0044S0C01
      B0042CO Bolt
      B0043VS Nut

      Remove the 3 bolts, nut and No. 1 fuel tank protector.

  10. DISCONNECT FUEL TANK BREATHER TUBE


    1. B0042OEC01
      *1 Fuel Tank Breather Tube
      *2 Fuel Tank To Filler Pipe Hose

      Loosen the clamp, then disconnect the fuel tank breather tube from the fuel tank filler pipe sub-assembly.

  11. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


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

  12. DISCONNECT FUEL RETURN TUBE SUB-ASSEMBLY

    Note

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


    1. Disconnect the fuel return tube sub-assembly from the fuel pipe.


      1. B0044OFC01
        *a Retainer
        *b Fuel Tube Connector
        *c Fuel Pipe
        *d O-ring
        *e Nylon Tube
        B0042CO Push
        B0043VS Pull off

        Push the retainer of the fuel tube connector, and then pull the fuel tube connector off of 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.

  13. 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. B0042J8C01
      *a Fuel Pipe
      *b Retainer
      *c O-ring
      *d Fuel Tube Connector
      *e Claw
      B0042CO Push
      B0043VS Pull out
      B0043HC Pull off

      Disconnect the fuel tank main tube sub-assembly from the fuel pipe.


      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).

      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.

  14. REMOVE FUEL TANK ASSEMBLY


    1. B0042LC

      Remove the 2 bolts and disconnect the parking brake cable assembly.

    2. B00422L

      Support the fuel tank assembly using an engine lifter.

      Tech Tips

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

    3. B0041SV

      Remove the 4 bolts.

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

      Note


      • Be careful not to drop the fuel tank assembly.

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

  15. REMOVE NO. 1 FUEL TANK CUSHION


    1. B0044RUC01
      *1 No. 1 Fuel Tank Cushion

      Remove the No. 1 fuel tank cushion from the fuel tank assembly.

  16. REMOVE NO. 2 FUEL TANK CUSHION (w/ No. 2 Fuel Tank Cushion)


    1. B0044P2C01
      *1 No. 2 Fuel Tank Cushion

      Remove the No. 2 fuel tank cushion from the fuel tank assembly.

  17. REMOVE FUEL RETURN TUBE SUB-ASSEMBLY


    1. B00439FC01
      *1 Fuel Return Tube Sub-assembly

      Disengage the 2 claws to remove the fuel return tube sub-assembly from the fuel tank assembly.

  18. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B0044FBC01
      *1 Fuel Tank Main Tube Sub-assembly

      Disengage the 2 claws to remove the fuel tank main tube sub-assembly from the fuel tank assembly.