FUEL TANK REMOVAL

Note

These procedures should be performed with the fuel tank less than 1/5 full.

REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
1. Remove the fuel suction tube assembly with pump and gauge Click here.
DRAIN FUEL
REMOVE FRONT FLOOR COVER LH
1. Remove the 4 bolts and floor cover.
DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Disconnect the fuel tank main tube sub-assembly.
  1. Pinch the tabs of the fuel tube connector retainer to disengage the lock claws and push the retainer down as shown in the illustration.
  2. Pull the fuel tank main tube sub-assembly out of the pipe.
    
    Note
    
    Check that there is no dirt or other foreign matter around the connector before disconnecting it. Clean the connector if necessary.
    
    It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
    
    Only disconnect the quick connector by hand.
    
    Do not bend, kink or twist the nylon tubes.
    
    Protect the connector by covering it with a plastic bag.
    
    If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY
1. Disconnect the purge line hose from the pipe.
REMOVE FUEL HOSE PROTECTOR
1. Using a screwdriver, release the 2 claws. Then remove the fuel hose protector from the fuel tank to filler pipe hose.
DISCONNECT FUEL TANK TO FILLER PIPE HOSE
1. Disconnect the filler pipe hose from the fuel tank.
DISCONNECT NO. 1 FUEL TANK BREATHER TUBE
1. Disconnect the breather tube from the fuel tank.
  Note
  
  Remove any dirt and foreign matter on the 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, twist or turn the nylon tube.
  
  Protect the disconnected part by covering it with a plastic bag and tape them after disconnecting the fuel tubes.
DISCONNECT CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY
1. Disconnect the charcoal canister outlet tube sub-assembly from the fuel filler pipe.
REMOVE FUEL TANK ASSEMBLY
1. Set a transmission jack underneath the fuel tank.
2. Remove the 6 bolts and 2 fuel tank bands.
3. Slightly lower the transmission jack.
REMOVE NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY
1. Remove the No. 1 fuel evaporation tube sub-assembly from the fuel tube clamps.
REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Remove the fuel tank main tube from the fuel tube clamps.
2. Remove the 2 tube clamps from the fuel tank.
REMOVE NO. 2 FUEL EVAPORATION TUBE SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Retainer
  
  *2 O-ring
  
  Remove the tube from the tank.
  Note
  - Remove any dirt and foreign matter on the 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-ring that seal the plug.
  - Perform this work by hand. Do not use any tools.
  - Do not forcibly bend, twist or turn the nylon tube.
  - Protect the disconnected part by covering it with a plastic bag and tape them after disconnecting the fuel tubes.
REMOVE CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY
1. Remove the charcoal canister outlet tube sub-assembly from the fuel tube clamps.
2. Remove the 2 tube clamps from the fuel tank.
REMOVE NO. 1 FUEL TANK PROTECTOR
1. Remove the 2 nuts and protector.
REMOVE REAR FUEL TANK BRACKET
1. Remove the 2 bolts and rear fuel tank bracket.
REMOVE FUEL TANK CUSHION
1. Remove the 6 fuel tank cushions from the fuel tank.

Text in Illustration
*1	Retainer
*2	O-ring