FUEL TANK (for TMC, TMMR Made) REMOVAL


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. DRAIN FUEL

  3. REMOVE CENTER EXHAUST PIPE ASSEMBLY

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  4. REMOVE NO. 1 FLOOR UNDER COVER


    1. for TMC Made:


      1. B000KKM

        Remove the screw.

        Text in Illustration
        B000K70 Nut (attached to under cover)
        B000IB9 Screw

      2. Disengage the 5 nuts and 2 clips, and remove the No. 1 floor under cover.

        Tech Tips

        Rotate the clips to disengage them. The 5 nuts and 2 clips will remain attached to the No. 1 floor under cover.

    2. for TMMR Made:


      1. B000I0H

        Disengage the 5 nuts and 2 clips, and remove the No. 1 floor under cover.

        Text in Illustration
        B000K70 Nut (attached to under cover)

        Tech Tips

        Rotate the clips to disengage them. The 5 nuts and 2 clips will remain attached to the No. 1 floor under cover.

  5. REMOVE NO. 2 FLOOR UNDER COVER


    1. for TMC Made:


      1. B000NFB

        Remove the screw and 2 clips.

        Text in Illustration
        B000K70 Nut (attached to under cover)
        B000IB9 Screw

      2. Disengage the 6 nuts and remove the No. 2 floor under cover.

        Tech Tips

        The 6 nuts will remain attached to the No. 2 floor under cover.

    2. for TMMR Made:


      1. B000LMW

        Remove the 2 clips.

        Text in Illustration
        B000K70 Nut (attached to under cover)

      2. Disengage the 6 nuts and remove the No. 2 floor under cover.

        Tech Tips

        The 6 nuts will remain attached to the No. 2 floor under cover.

  6. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. B000KO2

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

  7. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. B000NC4

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

  8. REMOVE REAR NO. 1 STABILIZER BAR BRACKET


    1. B000MRD

      Remove the 4 bolts and 2 rear No. 1 stabilizer bar brackets.

  9. REMOVE LOWER CENTER FUEL TANK PROTECTOR


    1. B000IFI

      Remove the 4 bolts and lower center fuel tank protector.

  10. DISCONNECT FUEL PUMP TUBE SUB-ASSEMBLY


    1. B000HHME02
      Text in Illustration
      *1 Retainer
      *2 Fuel Pipe
      *3 Fuel Tube Connector
      *4 O-ring
      *5 Fuel Pump Tube
      B000K70 Pinch
      B000IB9 Pull Out

      Pinch the tube connector and then pull out the fuel pump tube sub-assembly.

      Note


      • Check that there are no scratches or foreign matter around the connected 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 O-rings that seal the fuel pipe.

      • Only disconnect the fuel tube connector by hand.

      • Do not forcibly bend, twist or turn the fuel pump 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.

  11. REMOVE FUEL TANK ASSEMBLY


    1. B000MGK

      Loosen the clip, then disconnect the fuel emission hose from the charcoal canister.

    2. B000JAO

      Support the fuel tank using an engine lifter.

    3. B000MS7

      Remove the 2 bolts of the fuel tank bands.

    4. Slightly lower the engine lifter.

    5. B000HWO

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

    6. B000M1B

      Loosen the hose clamp bolt and disconnect the breather tube fuel hose.

    7. Lower the engine lifter to remove the fuel tank.

      Note


      • Slowly operate the engine lifter to lower the fuel tank.

      • Do not drop the fuel tank.

      • When removing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

    8. B000N8H

      Remove the 2 pins and 2 fuel tank bands as shown in the illustration.

    9. B000LC7

      Remove the 4 clip nuts.

  12. REMOVE NO. 1 FUEL TANK CUSHION


    1. B000HV9E01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion

      Remove the No. 1 fuel tank cushion.

  13. REMOVE NO. 2 FUEL TANK CUSHION


    1. Remove the 7 No. 2 fuel tank cushions.

  14. REMOVE NO. 2 FUEL TANK PROTECTOR


    1. B000M65E01

      Disengage the 2 claws, and remove the No. 2 fuel tank protector by sliding it as shown in the illustration.

  15. REMOVE NO. 3 FUEL TANK PROTECTOR


    1. B000JEKE01

      Disengage the 2 claws, and remove the No. 3 fuel tank protector by sliding it as shown in the illustration.

  16. REMOVE FUEL CUT OFF WITH TUBE VALVE ASSEMBLY


    1. B000IPZE02
      Text in Illustration
      *1 Fuel Cut Off Valve
      *2 Gasket

      Insert a clip remover between the fuel cut off valve and the gasket and remove the cut off valve by gradually pushing it upward.

      Note


      • Work carefully to maintain the sealing integrity of the valve as it is made from resin and easy to be damaged if forcibly removing and installing it.

      • Be sure to install a new fuel cut off valve and gasket.

    2. Separate the 2 No. 4 fuel tube clamps.

    3. Remove the 2 fuel tank breather tube gaskets.

  17. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY


    1. B000H0Z

      Disconnect the fuel main tube support, fuel tube clamp and remove the fuel pump tube sub-assembly.

  18. REMOVE FUEL MAIN TUBE SUPPORT


    1. B000N17

      Remove the bolt and fuel main tube support.

  19. REMOVE NO. 4 FUEL TUBE CLAMP


    1. B000NB8

      Remove the 3 No. 4 fuel tube clamps.