FUEL TANK(w/ Canister Pump Module) REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

    Click here

  3. DRAIN FUEL

  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  5. REMOVE REAR FLOOR SIDE MEMBER COVER LH (for Half Cover Type)

    Click here

  6. REMOVE REAR FLOOR SIDE MEMBER COVER RH (for Half Cover Type)

    Click here

  7. REMOVE NO. 1 FUEL TUBE PROTECTOR (for Half Cover Type)


    1. for LH Side:


      1. B0074MA

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

    2. for RH Side:


      1. B007771

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

  8. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B0077XD

      for LH Side:


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

        Click here

    2. B0074OB

      for RH Side:


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

        Click here

  9. 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.

  10. DISCONNECT FUEL CUT OFF VALVE TUBE

    Note

    Remove any foreign matter on the fuel cut off valve tube before performing this work.


    1. B0075DLC02
      *1 No. 1 Evaporation Vent Tube Clamp
      *a Retainer
      B0073AQ Pull out
      B0077IM Pull off

      Pull out the retainer to disengage the lock claws and pull off the fuel cut off valve tube from the fuel tank vent hose.

      Note


      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel cut off valve tube has an O-ring that seals the fuel tank vent hose.

      • Do not bend, twist, pinch or kink the fuel cut off valve tube.

    2. Disengage the clamp to disconnect the fuel cut off valve tube from the No. 1 evaporation vent tube clamp.

  11. DISCONNECT FUEL TANK BREATHER TUBE

    Note

    Remove any foreign matter on the fuel tank breather tube before performing this work.


    1. B0075OKC03
      *1 Breather Tube Clamp
      *a Retainer
      *b Claw
      B0073AQ Pull
      B0077IM Pull out
      B0077LI Pull off

      Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tank breather tube from the fuel tank filler pipe sub-assembly.

      Note


      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tank breather tube has an O-ring that seals the pipe (fuel tank filler pipe sub-assembly).

      • Do not bend, twist, pinch or kink the fuel tank breather tube.

    2. Disengage the clamp to disconnect the fuel tank breather tube from the breather tube clamp.

  12. SEPARATE PARKING BRAKE CABLE ASSEMBLY


    1. B00754LC04
      *1 No. 2 Parking Brake Cable Assembly
      *2 No. 3 Parking Brake Cable Assembly
      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.

  13. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

    Click here

  14. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

    Click here

  15. 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.

      • Be careful not to 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.

  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B0077WV

      Disengage the 2 clamps to remove the fuel tank main tube sub-assembly from the fuel tank assembly.

    2. B0076VKC01
      *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.

  17. REMOVE FUEL TANK CUSHION


    1. B0077DX

      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.

  18. 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.