FUEL TANK REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the fuel pump removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Performed Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of fuel pump Inspection after repair Poor idle, engine start, etc.

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CAUTION:

The fuel tank sub-assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank sub-assembly may fall off the engine lifter.

B003QTN

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.

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  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  4. REMOVE FUEL TANK CAP ASSEMBLY

  5. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. B003SFT

      Remove the 5 nuts and No. 1 fuel tank protector from fuel tank assembly.

  6. REMOVE NO. 3 FUEL TUBE CLAMP


    1. B003JGC

      Detach the 3 claw and remove the No. 3 fuel tube clamp from the fuel tube.

  7. DISCONNECT FUEL TUBE


    1. B003K30

      Disconnect the fuel tank main tube sub-assembly, fuel tank return tube and vent line tube.

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  8. DISCONNECT FUEL TANK BREATHER HOSE


    1. B003KVG

      Slide the clamp and disconnect the fuel tank breather hose from the fuel tank filler pipe sub-assembly.

  9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B003KV6

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

  10. REMOVE FUEL TANK ASSEMBLY


    1. Using an engine lifter and attachments, support the fuel tank assembly.

    2. B003OFX

      Remove the 3 bolts and disconnect the 3 fuel tank bands.

    3. Remove the 3 clips, 3 fuel tank band pins and 3 fuel tank bands.

      Tech Tips

      Move the fuel tank just enough to remove the pins.

    4. Slightly lower the engine lifter.

      Note

      Be careful not to cut the wire harness.

    5. B003JBBC01
      *1 Fuel Tank Cushion
      *2 Wire Harness
      *3 Fuel Tank Assembly

      Fold back approximately half of each fuel tank cushion so that the wire harness can be removed in the step below.

    6. B003PTM

      Disconnect the clamp and connector.

    7. B003P7A

      Detach the wire harness from the 6 clamps shown in the illustration.

    8. Disconnect the fuel sender gauge assembly connector from the fuel suction with pump and gauge tube assembly.

  11. REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    1. Remove the 2 nuts.

    2. B003LOIC01
      B003R2S No. 2 Fuel Tank Bracket
      B003LF2 Nut

      Using needle-nose pliers, remove the 4 No. 2 fuel tank brackets shown in the illustration, and then remove the No. 1 fuel tank heat insulator.

  12. REMOVE FUEL TANK CUSHION


    1. B003PHNC01
      *1 Fuel Tank Cushion

      Remove the 3 fuel tank cushions from the fuel tank assembly.

  13. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

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  14. REMOVE FUEL TANK TO FILLER PIPE HOSE

    B003KMM

    1. Loosen the clamp and remove the fuel tank to filler pipe hose from the fuel tank assembly.