FUEL TANK REMOVAL

PROCEDURE

1. PRECAUTION

   
   
   1. 

      Text in Illustration

      *1

      Cord

      When removing and storing the fuel tank assembly, arrange the fuel tank filler pipe assembly as shown in the illustration, and secure the fuel tank assembly using a cord or similar.

      Note

      According to the arrangement of the fuel tank filler pipe assembly during the storage, the fuel tank filler pipe assembly may become deform.

2. REMOVE FUEL TANK VENT TUBE WITH SENDER GAUGE ASSEMBLY

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3. REMOVE FUEL SUCTION TUBE SET GASKET

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4. DRAIN FUEL

5. REMOVE FRONT NO. 4 FLOOR HEAT INSULATOR

   
   

   1. 

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

6. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a	Pinch Point

      Pinch and remove the clip as shown in the illustration.

   2. Remove the bolt, nut and fuel tank cover vent case sub-assembly.

7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

   
   

   1. Release the checker as shown in the illustration.

      

      Text in Illustration

      *1	Retainer
      *2	Checker
      *3	Fuel Pipe
      *4	O-ring
      *5	Fuel Tube Connector
      *a	Pinch
      *b	Pull

   2. Pinch the retainer to release it as shown in the illustration and separate the fuel tank main tube.

      Note

      
      

      • Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.

      • The quick connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.

      • Do not use any tools.

      • Do not bend or twist the tubes.

      • Protect the contact surface by covering it with a plastic bag.

      • If the connector is stuck, push and pull on the parts to separate them.

8. DISCONNECT FUEL RETURN TUBE SUB-ASSEMBLY

   
   
   1. 

      Text in Illustration

      *1	Retainer
      *2	O-ring
      *3	Fuel Pipe
      *a	Lock
      *b	Unlock

      Release the lock as shown in the illustration.

   2. Pull the retainer and disconnect the fuel return tube.

      Note

      
      

      • Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.

      • The quick connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.

      • Do not use any tools.

      • Do not bend or twist the tubes.

      • Protect the contact surface by covering it with a plastic bag.

      • If the connector is stuck, push and pull on the parts to separate them.

9. REMOVE FUEL TANK ASSEMBLY

   
   

   1. 

      Remove the bolt and disconnect the clip, and disconnect the bracket.

   2. 

      Using an engine lifter, support the fuel tank.

   3. Remove the 4 bolts and the fuel tank.

      Note

      Make sure that the fuel tank does not fall.

10. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    
    

    1. 

       Disengage the guide and remove the fuel tank main tube from the fuel tank.

11. REMOVE FUEL RETURN TUBE SUB-ASSEMBLY

    
    

    1. 

       Disengage the guide and remove the fuel return tube from the fuel tank.

12. REMOVE FUEL HOSE CLAMP

    
    

    1. 

       Remove the fuel hose clamp.

13. REMOVE NO. 1 FUEL TANK FILLER PIPE SUPPORT

    
    

    1. 

       Remove the No. 1 fuel tank filler pipe support.

14. REMOVE NO. 2 FUEL TANK FILLER PIPE SUPPORT

    
    

    1. 

       Disengage the clamp and remove the No. 2 fuel tank filler pipe support.