FUEL TANK(w/o Canister Pump Module) REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

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  3. DRAIN FUEL

  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  5. 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. 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.

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

    Note

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


    1. B003V85C02
      *a Fuel Tube Connector
      *b Fuel Pipe
      *c Retainer
      *d O-ring
      B003WAF Pinch
      B003U82 Pull off

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


      1. Pinch 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 an O-ring that seals 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.

  7. 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.

  8. DISCONNECT FUEL TANK BREATHER TUBE


    1. B003WZE

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

    2. B003VMJC01
      *1 Breather Tube Clamp
      *2 No. 2 Evaporation Vent Tube Clamp

      Disengage the 2 clamps to disconnect the fuel tank breather tube from the breather tube clamp and No. 2 evaporation vent tube clamp.

  9. DISCONNECT CHARCOAL CANISTER OUTLET HOSE


    1. B003USX

      Disconnect the charcoal canister outlet hose from the No. 6 fuel tank breather tube.

  10. SEPARATE PARKING BRAKE CABLE ASSEMBLY


    1. B003WB6C02
      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.

  11. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

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  12. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

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  13. REMOVE FUEL TANK ASSEMBLY


    1. B003VMUC03
      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.

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


    1. B003WHY

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

  15. REMOVE CHARCOAL CANISTER OUTLET HOSE


    1. B003VLB

      Disengage the clamp to remove the charcoal canister outlet hose from the fuel tank assembly.

    2. B003WYA

      Disengage the clamp to remove the No. 4 fuel tube clamp from the fuel tank assembly.

  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B003TAI

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

    2. B003W1FC01
      *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.

  17. REMOVE FUEL TANK CUSHION


    1. B003TT4

      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.

  18. 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.