FUEL TANK(w/o Canister Pump Module) REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

    Click here

  3. DRAIN FUEL

  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  5. DISCONNECT FUEL TUBE


    1. B007426C01
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B0073AQ Push
      B0077IM Pull out
      B0077LI Pull off

      Disconnect the fuel tank main tube sub-assembly on the LH side.

      Note

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • 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.

        • Do not forcibly bend, twist or turn the nylon tube.

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    2. B00761JC01
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      B0073AQ Push
      B0077IM Pull out
      B0077LI Pull off

      Disconnect the fuel tank main tube sub-assembly on the RH side and fuel tank return tube.

      Note

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • 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.

        • Do not forcibly bend, twist or turn the nylon tube.

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    3. B0074APC01
      *a Retainer
      *b Fuel Tube Connector
      *c O-ring
      *d Fuel Pipe
      *e Claw
      B0073AQ Push
      B0077IM Pull out
      B0077LI Pull off

      Disconnect the No. 1 fuel evaporation tube sub-assembly.

      Note

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

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

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  6. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B0076BH

      Loosen the clamp, then disconnect the fuel tank to filler pipe hose from the fuel tank assembly.

  7. DISCONNECT FUEL TANK BREATHER TUBE


    1. B0072L0

      Loosen the clamp and disconnect the fuel tank breather tube from the fuel tank breather tube connector.

    2. B0077LLC01
      *1 Breather Tube Clamp
      *2 No. 2 Evaporation Vent Tube Clamp

      Disengage the 2 clamps to disconnect the fuel tank breather tube from the breather tube clamp and No. 2 evaporation vent tube clamp.

  8. DISCONNECT CHARCOAL CANISTER OUTLET HOSE


    1. B00769Q

      Disconnect the charcoal canister outlet hose from the No. 6 fuel tank breather tube.

  9. SEPARATE PARKING BRAKE CABLE ASSEMBLY


    1. B00754LC02
      B0073AQ Bolt
      B0077IM Nut

      Disengage the 4 clamps.

    2. Remove the 2 bolts and 2 nuts, and separate the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly.

  10. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

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  11. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

    Click here

  12. REMOVE FUEL TANK ASSEMBLY


    1. B0074SWC03
      B0073AQ Bolt
      B0077IM Nut

      Support the fuel tank assembly using an engine lifter.

      Tech Tips

      Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

    2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank band sub-assemblies.

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

      Note


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

      • Do not drop the fuel tank assembly.

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

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


    1. B00733Q

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

  14. REMOVE CHARCOAL CANISTER OUTLET HOSE


    1. B00764C

      Disengage the clamp to remove the charcoal canister outlet hose from the fuel tank assembly.

    2. B0073P5

      Disengage the clamp to remove the No. 4 fuel tube clamp from the fuel tank assembly.

  15. REMOVE FUEL TUBE


    1. B0072OEC03
      *1 Fuel Tank Return Tube
      *2 Fuel Tank Main Tube Sub-assembly

      Disengage the 4 clamps to remove the fuel tank return tube and fuel tank main tube sub-assembly from the fuel tank assembly.

    2. B0076KQC01
      *1 No. 3 Fuel Tube Clamp
      *2 No. 5 Fuel Tube Clamp

      Disengage the 2 clamps to remove the No. 3 fuel tube clamp and No. 5 fuel tube clamp from the fuel tank assembly.

  16. REMOVE FUEL TANK CUSHION


    1. B0077G8

      Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly.

    2. B0074AOC04
      *1 Fuel Tank Bracket
      *2 Fuel Tank Cushion
      *3 Fuel Tank Cushion Set
      *a RH Side
      *b LH Side

      Remove the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set from the fuel tank assembly.

  17. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. B0076IZC03
      *1 No. 1 Fuel Tank Protector Sub-assembly
      *2 No. 2 Fuel Tank Protector
      *3 No. 3 Fuel Tank Protector

      Remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.

    2. Remove the No. 2 fuel tank protector and No. 3 fuel tank protector from the fuel tank assembly.