FUEL TANK REMOVAL

PROCEDURE


  1. PRECAUTION


    1. A01V0EGE01
      Text in Illustration
      *1 Cord

      When removing and installing the fuel tank assembly, arrange the inlet hose as shown in the illustration, and secure the fuel tank assembly using a cord or similar.

      Note

      Depending on the arrangement of the inlet hose during removal, the inlet hose and rear suspension may interfere and cause fuel leaks.

  2. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  3. DRAIN FUEL

  4. REMOVE FUEL TANK CAP ASSEMBLY

  5. REMOVE FRONT NO. 4 FLOOR HEAT INSULATOR


    1. A01V022

      Remove the 2 nuts and front No. 4 floor heat insulator.

  6. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A01V1YK

      Pinch and remove the clip as shown in the illustration.

    2. Remove the bolt and No. 1 fuel tank protector sub-assembly.

  7. DISCONNECT NO. 2 FUEL EMISSION TUBE


    1. A01V06O

      Loosen the clip and disconnect the No. 2 fuel emission tube.

  8. REMOVE NO. 1 FUEL TUBE PROTECTOR


    1. A01V1O2E02
      Text in Illustration
      *1 No. 1 Fuel Tube Protector

      Remove the No. 1 fuel tube protector from the fuel tube connector.

  9. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank main tube sub-assembly.

      A01V0HXE01
      Text in Illustration
      *1 Fuel Tank Main Tube Sub-assembly
      *2 Fuel Tank Pipe Setting Holder
      *3 Retainer
      *4 Nylon Tube
      *5 O-ring
      *6 Fuel Tube Connector
      *7 Fuel Pipe
      *a Pull

      Note


      • Check that there is no damage or foreign matter around the connecting parts 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 nylon tube.

      • 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.

    2. Disengage the 3 clamps and separate the fuel tank pipe setting holder.

  10. REMOVE FUEL TANK ASSEMBLY


    1. A01UZY8E02
      Text in Illustration
      *1 Fuel Tank Filler Pipe Flange Plate
      *2 Air Tube

      Disengage the 2 clamps and separate the air tube.

    2. Remove the bolt.

    3. Disengage the claw and remove the fuel tank filler pipe flange plate.

    4. A01UY2N

      Support the fuel tank assembly using an engine lifter.

    5. A01V10O

      Disengage the 2 hose clamps and separate the 2 fuel hoses shown in the illustration.

    6. A01UXXU

      Remove the 4 bolts and fuel tank assembly.

      Note


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

      • Do not drop the fuel tank.

  11. REMOVE NO. 1 CANISTER OUTLET HOSE SUB-ASSEMBLY


    1. A01V1D4

      Disengage the clamp and remove the No. 1 canister outlet hose sub-assembly.

  12. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01UY03

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

  13. REMOVE NO. 2 FUEL EMISSION TUBE


    1. A01V07W

      Disengage the 2 clamps and remove the No. 2 fuel emission tube.

  14. REMOVE FUEL TANK FILLER PIPE PROTECTOR


    1. A01V24M

      Disengage the 4 claws and remove the fuel tank filler pipe protector and No. 2 fuel tank filler pipe protector.