FUEL TANK REMOVAL


  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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  2. DRAIN FUEL

  3. REMOVE CENTER EXHAUST PIPE ASSEMBLY

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  4. REMOVE NO. 1 FLOOR UNDER COVER


    1. for TMC Made:


      1. A01EZ35

        Remove the screw.

        Text in Illustration
        A01EUL1 Nut (attached to under cover)
        A01ETOA Screw

      2. Disengage the 5 nuts and 2 clips, and remove the No. 1 floor under cover.

        Tech Tips

        Rotate the clips to disengage them. The 5 nuts and 2 clips will remain attached to the No. 1 floor under cover.

    2. except TMC Made:


      1. A01EW56

        Disengage the 5 nuts and 2 clips, and remove the No. 1 floor under cover.

        Text in Illustration
        A01EUL1 Nut (attached to under cover)

        Tech Tips

        Rotate the clips to disengage them. The 5 nuts and 2 clips will remain attached to the No. 1 floor under cover.

  5. REMOVE NO. 2 FLOOR UNDER COVER


    1. for TMC Made:


      1. A01EWCI

        Remove the screw and 2 clips.

        Text in Illustration
        A01EUL1 Nut (attached to under cover)
        A01ETOA Screw

      2. Disengage the 6 nuts and remove the No. 2 floor under cover.

        Tech Tips

        The 6 nuts will remain attached to the No. 2 floor under cover.

    2. except TMC Made:


      1. A01EX7P

        Remove the 2 clips.

        Text in Illustration
        A01EUL1 Nut (attached to under cover)

      2. Disengage the 6 nuts and remove the No. 2 floor under cover.

        Tech Tips

        The 6 nuts will remain attached to the No. 2 floor under cover.

  6. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. A01EUE0

      Remove the bolt and nut of the No. 2 parking brake cable assembly.

  7. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. A01EU2J

      Remove the bolt and nut of the No. 3 parking brake cable assembly.

  8. REMOVE REAR NO. 1 STABILIZER BAR BRACKET


    1. A01ET48

      Remove the 4 bolts and 2 rear No. 1 stabilizer bar brackets.

  9. REMOVE LOWER CENTER FUEL TANK PROTECTOR


    1. A01ET57

      Remove the 4 bolts and lower center fuel tank protector.

  10. DISCONNECT FUEL PUMP TUBE SUB-ASSEMBLY


    1. A01ET65E02
      Text in Illustration
      *1 Retainer
      *2 Fuel Pipe
      *3 Fuel Tube Connector
      *4 O-ring
      *5 Fuel Pump Tube
      A01EUL1 Pinch
      A01ETOA Pull Out

      Pinch the tube connector and then pull out the fuel pump tube sub-assembly.

      Note


      • Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

      • Only disconnect the fuel tube connector by hand.

      • Do not forcibly bend, twist or turn the fuel pump tube.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.

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

  11. REMOVE FUEL TANK ASSEMBLY


    1. A01EVVP

      Loosen the clip, then disconnect the fuel emission hose from the charcoal canister.

    2. A01ET8F

      Support the fuel tank using an engine lifter.

    3. A01EXJJ

      Remove the 2 bolts of the fuel tank bands.

    4. Slightly lower the engine lifter.

    5. A01EXPY

      Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.

    6. A01EVTJ

      Loosen the hose clamp bolt and disconnect the breather tube fuel hose.

    7. 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.

    8. A01ET28

      Remove the 2 pins and 2 fuel tank bands as shown in the illustration.

    9. A01EVEL

      Remove the 4 clip nuts.

  12. REMOVE NO. 1 FUEL TANK CUSHION


    1. A01EXEAE01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion

      Remove the No. 1 fuel tank cushion.

  13. REMOVE NO. 2 FUEL TANK CUSHION


    1. Remove the 7 No. 2 fuel tank cushions.

  14. REMOVE NO. 2 FUEL TANK PROTECTOR


    1. A01ETAKE01

      Disengage the 2 claws, and remove the No. 2 fuel tank protector by sliding it as shown in the illustration.

  15. REMOVE NO. 3 FUEL TANK PROTECTOR


    1. A01EWQLE01

      Disengage the 2 claws, and remove the No. 3 fuel tank protector by sliding it as shown in the illustration.

  16. REMOVE FUEL CUT OFF WITH TUBE VALVE ASSEMBLY


    1. A01EW0HE02
      Text in Illustration
      *1 Fuel Cut Off Valve
      *2 Gasket

      Insert a clip remover between the fuel cut off valve and the gasket and remove the cut off valve by gradually pushing it upward.

      Note


      • Work carefully to maintain the sealing integrity of the valve as it is made from resin and easy to be damaged if forcibly removing and installing it.

      • Be sure to install a new fuel cut off valve and gasket.

    2. Separate the 2 No. 4 fuel tube clamps.

    3. Remove the 2 fuel tank breather tube gaskets.

  17. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY


    1. A01ET4R

      Disconnect the fuel main tube support, fuel tube clamp and remove the fuel pump tube sub-assembly.

  18. REMOVE FUEL MAIN TUBE SUPPORT


    1. A01EST7

      Remove the bolt and fuel main tube support.

  19. REMOVE NO. 4 FUEL TUBE CLAMP


    1. A01ESUS

      Remove the 3 No. 4 fuel tube clamps.