FUEL TANK REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. DRAIN FUEL

  3. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY

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  4. 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.

  5. REMOVE CHARCOAL CANISTER PROTECTOR

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


    1. A002ADI

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

  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0028MZC01
      *a Retainer
      *b O-ring
      *c Fuel Tube Connector
      *d Fuel Pipe
      B003ZIE Pull Out
      B003Z8F Pull Off

      Disconnect the fuel tank main tube sub-assembly.


      1. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

        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.

  8. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY


    1. A002CBUC01
      *a Retainer
      B003ZIE Pull
      B003Z8F Pull Out
      B003ZMU Pull Off

      Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tank vent hose sub-assembly.

      Note


      • Remove any dirt or foreign matter on the fuel tank vent hose sub-assembly before performing this work.

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

      • Only disconnect the fuel tank vent hose sub-assembly by hand.

      • Do not forcibly bend, twist or turn the fuel tank vent hose sub-assembly.

  9. DISCONNECT FUEL TANK BREATHER TUBE


    1. A0028WF

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

  10. REMOVE FUEL TANK ASSEMBLY


    1. A002A9WC01
      *1 Fuel Tank To Filler Pipe Hose
      *2 Fuel Tank To Filler Pipe Sub-assembly

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

    2. A002C1I

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

    3. A002AWE

      Remove the nut.

    4. A00292G

      Support the fuel tank assembly using an engine lifter.

      Tech Tips

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

    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


      • Do not drop the fuel tank assembly.

      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the other surrounding parts.

  11. REMOVE FUEL TANK SIDE PLATE


    1. A002AYRC01
      *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.

  12. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A002BDOC01
      *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.

  13. 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.

  14. REMOVE FUEL TANK CUSHION SET


    1. A0027SUC01
      *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.

  15. REMOVE TANK SUCTION TUBE SUPPORT


    1. A0026Y1

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