FUEL TANK REMOVAL

PROCEDURE

1. Click here

   REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

   (Click here)

2. Click here

   DRAIN FUEL

3. Click here

   REMOVE CENTER EXHAUST PIPE ASSEMBLY

   (Click here)

4. Click here

   REMOVE NO. 1 FLOOR UNDER COVER

   Click here

5. Click here

   REMOVE NO. 2 FLOOR UNDER COVER

   Click here

6. Click here

   DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY

   
   
   1. 

      Remove the nut and disconnect the No. 2 parking brake cable assembly.

      Table 1. Text in Illustration

      *1	No. 2 Parking Brake Cable Assembly
      *2	No. 3 Parking Brake Cable Assembly

7. Click here

   DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY

   
   

   1. Remove the nut and disconnect the No. 3 parking brake cable assembly.

8. Click here

   REMOVE REAR NO. 1 STABILIZER BAR BRACKET

   
   
   1. 

      Remove the 4 nuts and 2 rear No. 1 stabilizer bar brackets.

9. Click here

   REMOVE NO. 1 FUEL TANK PROTECTOR

   
   
   1. 

      Remove the 3 clips and No. 1 fuel tank protector.

10. Click here

    DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    
    
    1. 

       Pinch the tabs of the retainer to disengage the lock claws and pull it down as shown in the illustration.

       Table 2. Text in Illustration

       *1	Retainer
       *2	Tab
       *3	Fuel Tube Connector
       *4	Fuel Pipe
       *5	O-ring
       	Pinch
       	Pull

    2. Pull out the fuel tank main tube sub-assembly.

       Note:
       

       • Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before performing this work.

       • 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.

       • Only disconnect the fuel tube connector by hand.

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

       • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.

       • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

11. Click here

    DISCONNECT FUEL EMISSION HOSE

    
    
    1. 

       Loosen the clip and disconnect the fuel emission hose.

       Table 3. Text in Illustration

       *1	Fuel Emission Hose
       *2	No. 1 Charcoal Canister Outlet Hose

12. Click here

    DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE

    
    

    1. Loosen the clip and disconnect the No. 1 charcoal canister outlet hose.

13. Click here

    DISCONNECT FUEL TANK BREATHER HOSE

    
    
    1. 

       Loosen the clamp, then disconnect the fuel tank breather hose.

14. Click here

    DISCONNECT FUEL TANK TO FILLER PIPE HOSE

    
    
    1. 

       Pull the tab of the retainer to disengage the lock claws and pull out the fuel tank to filler pipe hose.

       Table 4. Text in Illustration

       *1	Retainer
       	Pull
       	Pull out

       Note:
       

       • Remove any dirt or foreign matter on the fuel tank to filler pipe hose connector before performing this work.

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

       • Only disconnect the fuel tank to filler pipe hose connector by hand.

       • Do not forcibly bend, twist or turn the fuel tank to filler pipe hose.

       • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank to filler pipe hose.

       • If the fuel tank to filler pipe hose connector and fuel tank sub-assembly are stuck, push and pull to release them.

15. Click here

    REMOVE FUEL TANK SUB-ASSEMBLY

    
    
    1. 

       Support the fuel tank sub-assembly using an engine lifter.

    2. 

       Remove the 4 bolts of the 2 fuel tank bands.

    3. Lower the engine lifter to remove the fuel tank sub-assembly.

       Note:
       

       • Slowly operate the engine lifter to lower the fuel tank sub-assembly.

       • Do not drop the fuel tank sub-assembly.

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

16. Click here

    REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    
    
    1. 

       Disconnect the No. 1 fuel tube clamp and remove the fuel tank main tube sub-assembly.

17. Click here

    DISCONNECT NO. 2 FUEL TUBE CLAMP

    
    
    1. 

       Disconnect the No. 2 fuel tube clamp and remove the charcoal canister outlet hose.

18. Click here

    REMOVE NO. 1 FUEL TUBE CLAMP

    
    
    1. 

       Remove the No. 1 fuel tube clamp.

19. Click here

    REMOVE FUEL TANK BREATHER HOSE

    
    
    1. 

       Loosen the clamp, then remove the fuel tank breather hose.

20. Click here

    REMOVE NO. 1 FUEL TANK CUSHION

    
    
    1. 

       Remove the 5 No. 1 fuel tank cushions.