FUEL TANK REMOVAL


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  2. DRAIN FUEL

  3. REMOVE TAIL EXHAUST PIPE ASSEMBLY


    1. A003ZCM

      Remove the 2 bolts and 2 compression springs.

    2. Remove the tail exhaust pipe assembly from the 3 exhaust pipe supports.

    3. Remove the gasket from the front exhaust pipe assembly.

  4. REMOVE REAR FLOOR SIDE MEMBER COVER LH (w/ Floor Under Cover)


    1. A003WROE01

      Remove the 2 bolts and nut.

    2. Disconnect the 2 clips, and remove the rear floor side member cover LH.

      Tech Tips

      Insert a screwdriver at an angle into the hole as shown in the illustration to disengage the claw of clip A.

  5. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A003Z9D

      Remove the 2 bolts, nut and No. 1 fuel tank protector.

  6. DISCONNECT FUEL TANK BREATHER TUBE


    1. A003Y5U

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

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

  7. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A003YPO

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

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


    1. A003ZFRE08
      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.

  9. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A003WLHE08
      Text in Illustration
      *1 Fuel Tube Connector Cover
      *2 Retainer
      *3 Fuel Tube Connector
      *4 Fuel Pipe
      *5 O-ring
      *a Pull
      *b Pinch

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

  10. REMOVE FUEL TANK ASSEMBLY


    1. A003YKF

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

    2. A003X0K

      Support the fuel tank using an engine lifter.

    3. A003WT0

      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.

  11. REMOVE NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A003Z20

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

  12. REMOVE NO. 1 FUEL TANK CUSHION


    1. A003WA7E01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion

      Remove the 3 No. 1 fuel tank cushions.

  13. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A003Y1X

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