FUEL TANK REMOVAL

Note

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


  1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

    Tech Tips

    Click here.

  2. DRAIN FUEL

  3. REMOVE FRONT FLOOR COVER LH


    1. A01CD5J

      Remove the 4 bolts and floor cover.

  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Disconnect the fuel tank main tube sub-assembly.


      1. A01CAM4E02

        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.

  5. DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A01CF8T

      Disconnect the purge line hose from the pipe.

  6. REMOVE FUEL HOSE PROTECTOR


    1. A01CAJA

      Using a screwdriver, release the 2 claws. Then remove the fuel hose protector from the fuel tank filler pipe hose.

  7. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01CCPJ

      Disconnect the filler pipe hose from the fuel tank.

  8. DISCONNECT NO. 1 FUEL TANK BREATHER TUBE


    1. A01CC1X

      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.

  9. DISCONNECT CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY


    1. A01CEV9

      Disconnect the charcoal canister outlet tube sub-assembly from the fuel filler pipe.

  10. REMOVE FUEL TANK ASSEMBLY


    1. Set a transmission jack underneath the fuel tank.

    2. A01CFHG

      Remove the 6 bolts and 2 fuel tank bands.

    3. Slightly lower the transmission jack.

  11. REMOVE NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A01CAMH

      Remove the No. 1 fuel evaporation tube sub-assembly from the fuel tube clamps.

  12. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01CAOD

      Remove the fuel tank main tube from the fuel tube clamps.

    2. Remove the 2 tube clamps from the fuel tank.

  13. REMOVE NO. 2 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A01CF24E01

      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-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.

  14. REMOVE CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY


    1. A01CC4V

      Remove the charcoal canister outlet tube sub-assembly from the fuel tube clamps.

    2. Remove the 2 tube clamps from the fuel tank.

  15. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A01CCY4

      Remove the 2 nuts and protector.

  16. REMOVE REAR FUEL TANK BRACKET


    1. A01CANE

      Remove the 2 bolts and rear fuel tank bracket.

  17. REMOVE FUEL TANK CUSHION


    1. A01CBDY

      Remove the 6 fuel tank cushions from the fuel tank.