FUEL TANK(w/ 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. REMOVE REAR FLOOR SIDE MEMBER COVER LH (for Half Cover Type)

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

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  7. DISCONNECT FUEL TUBE


    1. for Half Cover Type:


      1. A01MYZT

        Remove the 2 protectors from the fuel tank main tube sub-assembly and fuel tank return tube.

    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 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.

  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


    1. B003VL3C01
      *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.

      Note


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

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

      • Only disconnect the fuel cut off valve tube by hand.

      • Do not forcibly bend, twist or turn the fuel cut off valve tube.

    2. Disconnect the fuel cut off valve tube from the No. 1 evaporation tube clamp.

  10. DISCONNECT FUEL TANK BREATHER TUBE


    1. B003U1NC01
      *a Retainer
      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.

      Note


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

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

      • Only disconnect the fuel tank breather tube by hand.

      • Do not forcibly bend, twist or turn the fuel tank breather tube.

    2. Disconnect the fuel tank breather tube from the clamp.

  11. 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.

  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 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.

  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. B003W61

      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.