FUEL TANK REMOVAL


  1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

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  2. DRAIN FUEL

  3. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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  4. REMOVE REAR FLOOR SIDE MEMBER COVER LH


    1. A003SEN

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

  5. REMOVE REAR FLOOR SIDE MEMBER COVER RH

    Tech Tips

    Perform the same procedure as for the LH side.

  6. REMOVE REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY


    1. Remove the 4 bolts.

      A003SYR

    2. Disengage the clip and remove the rear floor side member brace sub-assembly.

  7. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A003SV0

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

  8. DISCONNECT FUEL TANK BREATHER TUBE


    1. A003TAW

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

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

  9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A003UX9

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

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


    1. A003T8DE08
      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 mud or dirt from entering the connector. If mud 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 tube between fingers, and turn the tube carefully to release it, then disconnect the tube.

  11. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A003TBCE08
      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 objects on the fuel tube connector before starting this step.

      • Avoid any scratches or foreign objects 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 connected part by covering it with a plastic bag after disconnecting the fuel tank main tube sub-assembly.

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

  12. REMOVE FUEL TANK ASSEMBLY


    1. A003SWN

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

    2. A003T4N

      Support the fuel tank using an engine lifter.

    3. A003TBD

      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.

  13. REMOVE NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A003TV9

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

  14. REMOVE NO. 1 FUEL TANK CUSHION


    1. A003TUPE01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion

      Remove the 3 No. 1 fuel tank cushions.

  15. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A003SOB

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