FUEL TANK REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

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

B003QTN

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine 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.

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  3. REMOVE FUEL TANK CAP ASSEMBLY

  4. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. B003SFT

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

  5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE


    1. B003MN7

      Slide the 2 clamps and disconnect the 2 fuel hoses from the fuel tank main tube sub-assembly and fuel tank return tube.

  6. DISCONNECT NO. 1 EVAPORATION TUBE SUB-ASSEMBLY


    1. B003QY2

      Disconnect the No. 1 evaporation tube sub-assembly from the fuel tank filler pipe sub-assembly.

  7. DISCONNECT FUEL TANK BREATHER HOSE


    1. B003JDJ

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

  8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B003OIN

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

  9. REMOVE FUEL TANK ASSEMBLY

    CAUTION:

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


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

    2. B003PBU

      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 assembly just enough to remove the fuel tank band pins.

    4. Slightly lower the engine lifter.

      Note

      Be careful not to cut the wire harness.

    5. B003QFQC01
      *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. B003PTI

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

    7. Disconnect the fuel sender gauge connector from the fuel tank vent tube assembly.

  10. REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    1. B003MC8C01
      B003R2S Fuel Tank Bolt
      B003LF2 Nut

      Remove the 2 nuts.

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

  11. REMOVE FUEL TANK CUSHION


    1. B003QWUC01
      *1 Fuel Tank Cushion

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

  12. REMOVE FUEL TANK VENT TUBE ASSEMBLY


    1. B003QZX

      Remove the 2 tube joint clips and pull out the fuel tank main tube sub-assembly and fuel tank return tube from the fuel tank vent tube assembly.

      Note

      B003OMRC01
      *a Fuel Tube Joint
      *b Fuel Tube
      *c O-Ring
      *d Tube Joint Clip

      • Remove any dirt and foreign matter on the fuel tube joint before performing this work.

      • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend or twist the nylon tube.

      • Protect the disconnected parts by covering them with plastic bags and tape after disconnecting the fuel tank main tube sub-assembly and fuel tank return tube.

    2. Remove the fuel pump gauge retainer from the fuel tank assembly.


      1. B003JDZC01
        *a SST (Plate)
        *b SST (Claw)
        *c Insertion point

        Set the 2 claws and plate of SST on the fuel pump gauge retainer.

        SST
        09808-14030   ( 09808-01010, 09808-01030, 09808-01040 )

        Tech Tips

        Securely insert the ends of SST into the insertion points in the fuel pump gauge retainer.

      2. While firmly pressing the claws of SST into the insertion points in the fuel pump gauge retainer, tighten the bolts of the claws.

      3. B003OWCN01

        Attach the handle of SST.

      4. While lightly pressing down on SST so it does not come off the fuel pump gauge retainer, slowly turn the handle and remove the fuel pump gauge retainer.

        Note


        • Do not use any tools other than SST, such as a screwdriver, etc.

        • Do not use excessive force when pressing down on SST, as the fuel pump gauge retainer will place excessive force on the fuel tank vent tube assembly and fuel pump gauge retainer and be difficult to remove, and parts may be damaged.

        • Be sure to keep the handle level when turning it, as SST may slip off the fuel pump gauge retainer if the handle is turned at an angle with excessive force.

        • Do not use an impact wrench or turn the handle with excessive force, as parts may be damaged.

        • If SST slips off the fuel pump gauge retainer, loosen the bolts and reattach SST to the fuel pump gauge retainer.

    3. Remove the fuel tank vent tube assembly from the fuel tank assembly.

      Note

      Be careful not to bend the arm of the fuel sender gauge assembly.

    4. B003MKN

      Remove the fuel tank vent tube gasket from the fuel tank assembly.

  13. REMOVE FUEL TANK TO FILLER PIPE HOSE

    B003R9C

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