FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

    Click here

  3. DRAIN FUEL

  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  5. DISCONNECT FUEL TUBE


    1. B003VGFC03
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      B003WAF Push
      B003U82 Pull Out
      B003WLN Pull Off

      Disconnect the fuel tank main tube sub-assembly for the LH side.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note


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

        • 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 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.

        • Do not forcibly bend, twist or turn nylon tube.

      3. Check if there is any 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.

    2. B003U0YC03
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      B003WAF Push
      B003U82 Pull Out
      B003WLN Pull Off

      Disconnect the fuel tank main tube sub-assembly for the RH side and fuel tank return tube.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note


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

        • 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 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.

        • Do not forcibly bend, twist or turn nylon tube.

      3. Check if there is any 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.

    3. B003WQXC02
      *a Retainer
      *b Fuel Tube Connector
      *c O-ring
      *d Fuel Pipe
      B003WAF Push
      B003U82 Pull Out
      B003WLN Pull Off

      Disconnect the No. 1 fuel evaporation tube sub-assembly.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note


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

        • 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 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.

        • Do not forcibly bend, twist or turn nylon tube.

      3. Check if there is any 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 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.

  7. DISCONNECT FUEL TANK BREATHER TUBE


    1. B003WZE

      Loosen the clamp and disconnect the fuel tank breather tube from the fuel tank breather tube connector.

    2. B003VMJ

      Disconnect the fuel tank breather tube from the 2 hose clamps.

  8. DISCONNECT CHARCOAL CANISTER OUTLET HOSE


    1. B003USX

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

  9. DISCONNECT PARKING BRAKE CABLE ASSEMBLY


    1. B003U9Y

      Remove the 2 bolts, 2 nuts and 4 clamps, and disconnect the No. 2 parking brake cable and No. 3 parking brake cable.

  10. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

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  11. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

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  12. REMOVE FUEL TANK ASSEMBLY


    1. B003VJOC03
      B003WAF Bolt
      B003U82 Nut

      Support the fuel tank assembly using an engine lifter.

      Tech Tips

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

    2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank bands.

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

      Note


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

      • 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.

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


    1. B003T7O

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

  14. REMOVE CHARCOAL CANISTER OUTLET HOSE


    1. B003TYL

      Remove the charcoal canister outlet hose and No. 4 fuel tube clamp from the fuel tank assembly.

  15. REMOVE FUEL TUBE


    1. B003SVZC02
      *1 Fuel Tank Return Tube
      *2 Fuel Tank Main Tube Sub-assembly

      Disengage the clamp and remove the fuel tank return tube and fuel tank main tube sub-assembly from the fuel tank assembly.

    2. Remove the No. 5 fuel tube clamp from the fuel tank assembly.

  16. REMOVE FUEL TANK CUSHION


    1. B003TT4

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

    2. B003UH9C03
      *1 Fuel Tank Bracket
      *2 Fuel Tank Cushion
      *3 Fuel Tank Cushion Set
      *a RH side
      *b LH side

      Remove the fuel tank bracket, 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.