FUEL TANK REMOVAL


  1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

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  2. DRAIN FUEL

  3. REMOVE REAR FLOOR SIDE MEMBER COVER LH


    1. A01J8O5

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

  4. REMOVE REAR FLOOR SIDE MEMBER COVER RH


    1. A01JA88

      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.

      A01JD65

    2. Disengage the clip and remove the rear suspension brace sub-assembly.

  6. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A01JCCY

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

  7. DISCONNECT FUEL TANK BREATHER TUBE


    1. A01J8FH

      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. A01J8G0

      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. A01JCIRE08
      Text in Illustration
      *1 Rubber Hose
      *2 O-ring
      *3 Fuel Pipe
      *4 Retainer
      *a Turn
      *b Pull Out

      Pinch the projections of the retainer to disengage the lock claws, and pull it 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 dirt or foreign matter from entering the connector. If dirt or foreign matter enters the connector, the O-ring may not seal properly.

      • Do not use any tools for this work.

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

      • If the connector and the pipe are stuck, pinch the retainer, and turn the tube carefully to release it, then disconnect the tube.

  10. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01JBXPE08
      Text in Illustration
      *1 Lock Cover
      *2 Retainer
      *3 Fuel Tube Connector
      *4 Fuel Pipe
      *5 O-ring
      *a Pull
      *b Pinch

      Release the lock as shown in the illustration, then pull and remove the fuel tank main tube sub-assembly.

    2. Pull out the fuel tank main tube sub-assembly from the pipe.

      Note


      • Remove any dirt or foreign matter on the fuel tube connector before starting this step.

      • Avoid any scratches or foreign matter on the parts when disconnecting as the fuel tube connector has the O-ring that seals the pipe.

      • Perform this work by hand. Do not use any tools.

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

      • Protect the disconnected parts by covering them with plastic bags after disconnecting the fuel tank main tube sub-assembly.

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

  11. REMOVE FUEL TANK ASSEMBLY


    1. A01JAZI

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

    2. A01J8DY

      Support the fuel tank using an engine lifter.

    3. A01J95E

      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. A01JB1S

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

  13. REMOVE NO. 1 FUEL TANK CUSHION


    1. A01J9OCE01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion

      Remove the 3 No. 1 fuel tank cushions.

  14. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A01JCIG

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