FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  2. DRAIN FUEL

  3. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY (for 2WD)

    Click here

  4. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY (for AWD)

    Click here

  5. REMOVE FRONT CENTER FLOOR COVER


    1. A002C9PC01
      B003ZIE Screw
      B003Z8F Nut

      Remove the 2 screws and nut.

    2. Disengage the 4 clips to remove the front center floor cover.

  6. REMOVE CHARCOAL CANISTER PROTECTOR

    Click here

  7. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. A0027M4

      Remove the 4 clips, 7 nuts and No. 1 fuel tank protector sub-assembly.

  8. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0029KT

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

      Click here

  9. DISCONNECT FUEL TANK BREATHER TUBE


    1. A0028WF

      Loosen the clamp, then disconnect the fuel tank breather tube from the fuel tank filler pipe assembly.

  10. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A002A9W

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

  11. REMOVE FUEL TANK ASSEMBLY


    1. A0028NR

      Disconnect the fuel cut off valve with tube assembly from the charcoal canister assembly.

      Click here

    2. A002C1I

      Remove the bolt, nut and rear fuel tank bracket LH.

    3. A002AWE

      Remove the nut.

    4. A002AY7

      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.

    5. Remove the 4 bolts, No. 1 fuel tank band sub-assembly LH and No. 1 fuel tank band sub-assembly RH.

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

      Note


      • 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 surrounding parts.

  12. REMOVE FUEL TANK SIDE PLATE


    1. A002BZUC01
      *1 Fuel Tank Band Pin
      *2 Fuel Tank Cushion

      Remove the fuel tank band pin, fuel tank cushion and fuel tank side plate from the fuel tank assembly.

  13. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A002CFQC01
      *1 Fuel Tank Main Tube Sub-assembly

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

  14. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A002A7D

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

  15. REMOVE FUEL TANK CUSHION SET


    1. A0027LHC01
      *1 Fuel Tank Cushion Set
      *2 No. 5 Fuel Tank Cushion

      Remove the 2 fuel tank cushion sets and 2 No. 5 fuel tank cushions from the fuel tank assembly.

  16. REMOVE TANK SUCTION TUBE SUPPORT


    1. A002AIO

      Remove the tank suction tube support from the fuel tank assembly.