FUEL TANK REMOVAL


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. DRAIN FUEL

  3. REMOVE REAR FLOOR SIDE MEMBER COVER LH


    1. A00434K

      Remove the nut, 2 bolts and rear floor side member cover LH.

  4. REMOVE REAR FLOOR SIDE MEMBER COVER RH


    1. A0040WN

      Remove the 3 bolts.

    2. Disengage the clip and remove the rear floor side member cover RH.

  5. REMOVE REAR SUSPENSION BRACE SUB-ASSEMBLY


    1. Remove the 4 bolts and the rear suspension brace sub-assembly.

      A00406J

  6. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A0042ZS

      Remove the 3 bolts and No. 1 fuel tank protector.

  7. DISCONNECT FUEL TANK BREATHER TUBE


    1. A00411V

      Loosen the clip, then disconnect the fuel tank breather tube from the fuel vent tube.

    2. Disconnect the No. 1 charcoal canister outlet hose.

  8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A0040PX

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

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


    1. A0041PTE09
      Text in Illustration
      *1 Rubber Hose
      *2 O-ring
      *3 Fuel Pipe
      *4 Retainer
      *5 Fuel Tube Connector
      *a Turn
      *b Pull Out

      Pinch the projections of the retainer to disengage the lock claws, and pull fuel tube connector out as shown in the illustration.

      Note


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

      • It is necessary to prevent mud or dirt from entering the fuel tube connector. If mud enters the fuel tube connector, the O-ring may not seal properly.

      • Do not use any tools for this work.

      • After disconnecting the fuel tube connector, cover the fuel tube connector with a plastic bag.

      • If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to release them. Pull the fuel tube connector out of the fuel pipe carefully.

  10. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0042S7E08
      Text in Illustration
      *1 Lock Cover
      *2 Retainer
      *3 Fuel Tube Connector
      *4 Fuel Pipe
      *5 O-ring
      *a Pull
      *b Pinch

      Pull the lock cover of the fuel tank main tube sub-assembly.

    2. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

      Note


      • Check for foreign matter on the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe.

      • Do not use any tools to separate the fuel tube connector and fuel pipe.

      • Do not forcefully bend, kink or twist the fuel tank main tube.

      • Keep the fuel tube connector and fuel pipe free from foreign matter.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

      • Put the fuel tube connector and fuel pipe in plastic bags to prevent damage and contamination.

  11. REMOVE FUEL TANK ASSEMBLY


    1. A0040OK

      Remove the 2 bolts and disconnect the parking brake cable assembly.

    2. A0040V4

      Support the fuel tank using an engine lifter.

    3. A0040YE

      Remove the 4 set bolts of the 2 fuel tank bands.

    4. Lower the engine lifter to remove the fuel tank.

      Note


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

      • Do not drop the fuel tank.

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

  12. REMOVE NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A0041YC

      Remove the No. 1 charcoal canister outlet hose and hose clamp.

  13. REMOVE NO. 1 FUEL TANK CUSHION


    1. A0042DC

      Remove the 3 No. 1 fuel tank cushions.

  14. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A003ZX6

      Remove the 2 fuel tank cover vent case sub-assemblies.