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FUEL TANK(w/ Canister Pump Module) REMOVAL

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PROCEDURE


  1. Click here

    REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. Click here

    REMOVE FUEL TANK VENT TUBE ASSEMBLY

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  3. Click here

    DRAIN FUEL

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    REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  5. Click here

    DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B0065XCC01
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B0067U9 Push
      B00679M Pull out
      B00683Y Pull off

      Disconnect the fuel tank main tube sub-assembly on the LH side.

      Note:

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note:

        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.

    2. B00687AC01
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B0067U9 Push
      B00679M Pull out
      B00683Y Pull off

      Disconnect the fuel tank main tube sub-assembly on the RH side.

      Note:

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note:

        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.

  6. Click here

    DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B006883

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

  7. Click here

    DISCONNECT FUEL CUT OFF VALVE TUBE

    Note:

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


    1. B0065XLC01
      *1 No. 1 Evaporation Vent Tube Clamp
      *a Retainer
      B0067U9 Pull
      B00679M Pull off

      Pull out the retainer to disengage the lock claws and pull off the fuel cut off valve tube.

      Note:

      • 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.

      • Be sure to disconnect the fuel cut off valve tube by hand.

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

    2. Disengage the clamp to disconnect the fuel cut off valve tube from the No. 1 evaporation vent tube clamp.

  8. Click here

    DISCONNECT FUEL TANK BREATHER TUBE

    Note:

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


    1. B006764C01
      *1 Breather Tube Clamp
      *a Retainer
      *b Claw
      B0067U9 Pull
      B00679M Pull out
      B00683Y Pull off

      Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tank breather tube.

      Note:

      • 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.

      • Be sure to disconnect the fuel tank breather tube by hand.

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

    2. Disengage the clamp to disconnect the fuel tank breather tube from the breather tube clamp.

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    SEPARATE PARKING BRAKE CABLE ASSEMBLY


    1. B006707C02
      B0067U9 Bolt
      B00679M 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.

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    REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

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  11. Click here

    REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

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    REMOVE FUEL TANK ASSEMBLY


    1. B0065R7C01
      B0067U9 Bolt
      B00679M Nut

      Support the fuel tank assembly using an engine lifter.

      Tip:

      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.

      • 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. Click here

    REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B0067U4

      Disengage the 2 clamps to remove the fuel tank main tube sub-assembly from the fuel tank assembly.

    2. B00666AC01
      *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.

  14. Click here

    REMOVE FUEL TANK CUSHION


    1. B0065BO

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

    2. B006588C04
      *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.

  15. Click here

    REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. B0066G3C03
      *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.