FUEL TANK(w/ Canister Pump Module) REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

    Click here

  3. DRAIN FUEL

  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  5. REMOVE REAR FLOOR SIDE MEMBER COVER LH (for Half Cover Type)

    Click here

  6. REMOVE REAR FLOOR SIDE MEMBER COVER RH (for Half Cover Type)

    Click here

  7. 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. for Half Cover Type:


      1. B003WU3

        Remove the 2 No. 1 fuel tube protectors from the fuel tank main tube sub-assembly.

    2. B003UR8C01
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B003WAF Push
      B003U82 Pull out
      B003WLN 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).

        • 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.

  8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B003X5R

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

  9. DISCONNECT FUEL CUT OFF VALVE TUBE

    Note

    Remove any dirt or foreign matter on the fuel cut off valve tube before performing this work.


    1. B003VL3C02
      *1 No. 1 Evaporation Vent Tube Clamp
      *a Retainer
      B003WAF Pull
      B003U82 Pull off

      Pull out the retainer to disengage the lock claws and pull off the fuel cut off valve tube from the fuel tank vent hose.

      Note


      • Be sure to disconnect the fuel cut off valve tube by hand.

      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel cut off valve tube has an O-ring that seals the fuel tank vent hose.

      • Do not bend, twist, pinch or kink the fuel cut off valve tube.

    2. Disengage the clamp to disconnect the fuel cut off valve tube from the No. 1 evaporation vent tube clamp.

  10. DISCONNECT FUEL TANK BREATHER TUBE

    Note

    Remove any dirt or foreign matter on the fuel tank breather tube before performing this work.


    1. B003U1NC03
      *1 Breather Tube Clamp
      *a Retainer
      *b Claw
      B003WAF Pull
      B003U82 Pull out
      B003WLN Pull off

      Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tank breather tube from the fuel tank filler pipe sub-assembly.

      Note


      • Be sure to disconnect the fuel tank breather tube by hand.

      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tank breather tube has an O-ring that seals the pipe (fuel tank filler pipe sub-assembly).

      • Do not bend, twist, pinch or kink the fuel tank breather tube.

    2. Disengage the clamp to disconnect the fuel tank breather tube from the breather tube clamp.

  11. SEPARATE PARKING BRAKE CABLE ASSEMBLY


    1. B003WB6C04
      *1 No. 2 Parking Brake Cable Assembly
      *2 No. 3 Parking Brake Cable Assembly
      B003WAF Bolt
      B003U82 Nut

      Disengage the 4 clamps.

    2. Remove the 2 bolts and 2 nuts, and separate the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly.

  12. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

    Click here

  13. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

    Click here

  14. REMOVE FUEL TANK ASSEMBLY


    1. B003VJOC03
      B003WAF Bolt
      B003U82 Nut

      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.

    2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank band sub-assemblies.

    3. 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 suspension arm or other surrounding parts.

  15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B003V31

      Disengage the 3 clamps to remove the fuel tank main tube sub-assembly from the fuel tank assembly.

    2. B003VI8C01
      *1 No. 3 Fuel Tube Clamp
      *2 No. 5 Fuel Tube Clamp

      Disengage the 2 clamps to remove the No. 3 fuel tube clamp and No. 5 fuel tube clamp from the fuel tank assembly.

  16. REMOVE FUEL TANK CUSHION


    1. B003W61

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

    2. B003UH9C04
      *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.

  17. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. B003U49C03
      *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.