FUEL TANK 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. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B003V3D

      for LH Side:


      1. Disconnect the fuel tank main tube sub-assembly from the fuel pipe.

        Click here

    2. B003WDN

      for RH Side:


      1. Disconnect the fuel tank main tube sub-assembly from the fuel pipe.

        Click here

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


    1. B003T04

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

      Click here

  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

    Click here

  12. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

    Click here

  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. B003UGJ

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

  15. REMOVE CHARCOAL CANISTER OUTLET HOSE


    1. B003UJD

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

    2. B003VKB

      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. B003TT2

      Disengage the 2 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.