FUEL TANK 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. 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.

  5. 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.

  6. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. B000LJC

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

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut

  7. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. B000IIS

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

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut

  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. B000NQME01
      Text in Illustration
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B000K70 Push
      B000IB9 Pull out
      B000JQI Pull off

      Disconnect the fuel pump tube sub-assembly.

      Note

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


      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).

        • 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.

  11. REMOVE FUEL TANK ASSEMBLY


    1. B000HZT

      Slide the clip and disconnect the fuel emission hose from the charcoal canister assembly.

    2. B000HWO

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

    3. B000M1B

      Loosen the clamp, then disconnect the breather tube fuel hose from the fuel tank assembly.

    4. B000JAO

      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.

    5. B000MS7

      Remove the 2 bolts of the fuel tank bands.

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

      Note


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

      • 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.

    7. B000N8HE01
      Text in Illustration
      *1 Pin
      *2 Fuel Tank Band

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

    8. B000LAH

      Remove the 4 clip nuts from the fuel tank assembly.

  12. REMOVE NO. 1 FUEL TANK CUSHION


    1. B000J0E

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

  13. REMOVE NO. 2 FUEL TANK CUSHION


    1. B000L52

      Remove the 7 No. 2 fuel tank cushions from the fuel tank assembly.

  14. REMOVE NO. 2 FUEL TANK PROTECTOR


    1. B000LRD

      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. B000JNY

      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. B000N9DE01
      Text in Illustration
      *1 Fuel Tank Breather Tube Gasket
      *2 Fuel Cut Off with Tube Valve Assembly
      *3 Fuel Emission Hose
      *a Fuel Cut Off Valve

      Slide the clip and disconnect the fuel emission hose from the fuel cut off with tube valve assembly.

    2. Disengage the 2 clamps to disconnect the fuel cut off with tube valve assembly from the fuel tank assembly.

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

      Note


      • Work carefully to maintain the sealing integrity of the fuel cut off 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 with tube valve assembly and 2 new fuel tank breather tube gaskets.

    4. Remove the 2 fuel tank breather tube gaskets from the fuel tank assembly.

  17. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY


    1. B000L45

      Disengage the 4 clamps to remove the fuel pump tube sub-assembly from the fuel tank assembly.

  18. REMOVE FUEL MAIN TUBE SUPPORT


    1. B000LX8

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

  19. REMOVE NO. 1 FUEL TUBE CLAMP


    1. B000H98

      Disengage the 2 claws to remove the 2 No. 1 fuel tube clamps from the fuel tank assembly.

  20. REMOVE NO. 2 FUEL TUBE CLAMP


    1. B000L3F

      Disengage the claw to remove the No. 2 fuel tube clamp from the fuel tank assembly.