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

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  3. DRAIN FUEL

  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  5. DISCONNECT FUEL TUBE


    1. w/ Protector:


      1. B003XPM

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

    2. B003YFRC03
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      B003XUN Push
      B003YHT Pull Out
      B003XOB Pull Off

      Disconnect the fuel tank main 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 O-rings that seal the fuel pipe.

        • Do not forcibly bend, twist or turn the 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. w/ Protector:


      1. B003YNN

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

    4. B003XO5C02
      *a Retainer
      *b Fuel Tube Connector
      *c O-ring
      *d Fuel Pipe
      B003XUN Push
      B003YHT Pull Out
      B003XOB 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 O-rings that seal the fuel pipe.

      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. B003XWB

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

  7. DISCONNECT FUEL TANK BREATHER TUBE


    1. B003XQ9

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

    2. B003YKU

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

  8. DISCONNECT CHARCOAL CANISTER OUTLET HOSE


    1. B003YQJ

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

  9. DISCONNECT PARKING BRAKE CABLE ASSEMBLY


    1. B003YM0

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

  10. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

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  11. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

    Click here

  12. REMOVE FUEL TANK ASSEMBLY


    1. B003YS4C03
      B003XUN Bolt
      B003YHT 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 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.

      • 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. B003XTE

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

  14. REMOVE CHARCOAL CANISTER OUTLET HOSE


    1. B003Y32

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

  15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B003YOU

      Disengage the clamp and remove the 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. B003Y9B

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

    2. B003Y7QC03
      *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. B003YPDC03
      *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.