FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. DRAIN FUEL

  3. REMOVE REAR FLOOR SIDE MEMBER COVER LH

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  4. REMOVE REAR FLOOR SIDE MEMBER COVER RH

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  5. REMOVE REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY

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  6. REMOVE CENTER EXHAUST PIPE ASSEMBLY

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  7. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A00Y5YN

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

  8. DISCONNECT FUEL TANK BREATHER TUBE


    1. A00YAI8C01
      *1 No. 1 Charcoal Canister Outlet Hose
      *2 Fuel Tank Breather Tube

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

  9. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. Disconnect the No. 1 charcoal canister outlet hose from the fuel tank filler pipe sub-assembly.

  10. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A00Y9YJ

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

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


    1. A00Y9XCC02
      *a Fuel Pipe
      *b Rubber Hose
      *c Retainer
      *d O-ring
      A00Y51D Turn
      A00YA05 Pull

      Turn the projections of the retainer to disengage the lock claws, and then pull off the No. 1 fuel evaporation tube sub-assembly.

      Note


      • Check that there are no scratches or foreign matter around the connecting part of the fuel tube connector and fuel pipe before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the fuel pipe.

      • Only disconnect the fuel tube connector by hand.

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

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

  12. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A00Y9M3C02
      *a Retainer
      *b Fuel Tube Connector Cover
      *c Fuel Tube Connector
      *d Fuel Pipe
      *e Nylon Tube
      *f O-ring

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

      Note


      • Check that there are no scratches or foreign matter on the connecting parts of the fuel tube connector and fuel pipe before performing this work.

      • 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.

      • Only disconnect the fuel tube connector by hand.

      • 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 tube connector.

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

  13. REMOVE FUEL TANK ASSEMBLY


    1. A00Y7WP

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

    2. A00Y6PB

      Support the fuel tank assembly using an engine lifter.

      Tech Tips

      Using a height adjustable attachment and plate lift attachment, place the fuel tank assembly horizontally.

    3. A00Y8LA

      Remove the 4 bolts.

    4. 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.

  14. REMOVE NO. 1 FUEL TANK CUSHION


    1. A00Y7T0C01
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion

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

  15. REMOVE NO. 2 FUEL TANK CUSHION


    1. Remove the 3 No. 2 fuel tank cushions from the fuel tank assembly.

  16. REMOVE NO. 4 FUEL TANK CUSHION


    1. A00YB0T

      Remove the No. 4 fuel tank cushion from the fuel tank assembly.

  17. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A00Y8GMC01
      *1 Fuel Tank Main Tube Sub-assembly

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

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


    1. A00Y7ZZC01
      *1 No. 1 Fuel Evaporation Tube Sub-assembly

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

  19. REMOVE NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A00YAMA

      Disconnect the clamp, and remove the No. 1 charcoal canister outlet hose from the fuel tank assembly.