FUEL TANK REMOVAL


  1. REMOVE EXHAUST PIPE ASSEMBLY


    1. Remove the exhaust pipe assembly Click here.

  2. REMOVE REAR NO. 1 SEAT ASSEMBLY (w/ Rear No. 1 Seat)


    1. Remove the rear No. 1 seat assembly Click here.

  3. REMOVE REAR CENTER SEAT ASSEMBLY (w/ Rear No. 1 Seat)


    1. Remove the rear center seat assembly Click here.

  4. REMOVE REAR FLOOR SERVICE HOLE COVER


    1. A01IUNL

      Remove the butyl tape and service hole cover.

    2. Disconnect the fuel sender gauge connector.

  5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01ISQRE01
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Tank Vent Tube

      Remove the tube joint clip and pull out the fuel tank main tube.

      Note


      • Remove any dirt and foreign matter on the fuel tube joint before performing this step.

      • Do not scratch or allow any foreign matter to adhere to the parts when disconnecting them as the fuel tube joint contains the O-rings that seal the plug.

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

      • Do not forcibly bend or twist the nylon tube.

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

  6. DISCONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A01IO3VE01
      Text in Illustration
      *1 Fuel Tube Joint
      *2 Tube Joint Clip
      *3 O-Ring
      *4 Fuel Tank Vent Tube

      Remove the tube joint clip and pull out the fuel return tube.

      Note


      • Remove any dirt and foreign matter on the fuel tube joint before performing this step.

      • Do not scratch or allow any foreign matter to adhere to the parts when disconnecting them as the fuel tube joint contains the O-rings that seal the plug.

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

      • Do not forcibly bend or twist the nylon tube.

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

  7. REMOVE FUEL PUMP GAUGE RETAINER


    1. A01INQ1E01
      Text in Illustration
      *1 SST (Plate)
      *2 SST (Claw)

      Temporarily install SST (plate and 2 claws) to the fuel pump gauge retainer.

      SST
      09808-14030

      Tech Tips


      • Be sure to use 2 SST (claws) as shown in the illustration.

      • Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.

    2. While securely pressing SST (claws) against the fuel pump gauge retainer ribs, install the 2 bolts.

      Tech Tips

      Install SST while pressing SST (claws) against the fuel pump gauge retainer (towards the center of SST).

    3. Install SST (handle).

    4. A01IRFVE02

      Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing SST, rotate the handle slowly to loosen the fuel pump gauge retainer.

      SST
      09808-14030
      Text in Illustration
      A01ISM9 Turn

      Note


      • Do not use any tools other than those specified in this operation. Damage to the fuel pump gauge retainer or fuel tank may result.

      • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate and may damage components.

      • Make sure to rotate SST (handle) horizontally. If SST (handle) is rotated at an angle, SST may come off.

      • Do not spin SST too fast or use an impact wrench as this may result in damage to components.

      • If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.

      Tech Tips

      The tips of SST (claws) can be fitted onto the ribs of the fuel pump gauge retainer.

    5. Remove the fuel pump gauge retainer.

  8. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. Remove the fuel tank vent tube from the fuel tank.

      Note

      Make sure that the fuel sender gauge arm does not bend.

    2. A01IUCYE03
      Text in Illustration
      *1 Gasket

      Remove the gasket from the fuel tank.

  9. DRAIN FUEL

  10. REMOVE FRONT FLOOR CENTER COVER LH


    1. A01IPP0E01
      Text in Illustration
      *1 Grommet

      Remove the nut, detach the grommet and remove the front floor center cover LH.

  11. REMOVE FRONT FLOOR CENTER COVER RH


    1. A01IO5ME01
      Text in Illustration
      *1 Grommet

      Remove the nut, detach the grommet and remove the front floor center cover RH.

  12. REMOVE REAR FLOOR SIDE MEMBER COVER LH


    1. A01IN3J

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

  13. REMOVE REAR FLOOR SIDE MEMBER COVER RH


    1. A01ISBE

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

  14. REMOVE REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY


    1. A01IQ5KE01
      Text in Illustration
      *1 Clip

      Remove the 4 bolts, detach the clip and remove the rear floor side member brace.

  15. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A01IPFA

      Using needle-nose pliers, remove the 4 clips and No. 1 fuel tank protector.

    2. A01IPOK

      Remove the fuel tank protector cushion.

  16. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01IQIK

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

  17. REMOVE FUEL TANK ASSEMBLY


    1. A01IS4W

      Loosen the hose clamp bolt, and then disconnect the breather hose.

    2. A01IOYM

      Remove the 2 bolts and disconnect the parking brake cable.

    3. Disconnect the fuel tank return tube.


      1. A01IUMVE01
        Text in Illustration
        *1 Retainer
        *2 Fuel Tube Connector
        *3 O-Ring
        *4 Pipe

        Pinch the tabs of the retainer of the fuel tube connector to detach the lock claws and push the retainer down as shown in the illustration.

      2. Pull the fuel tank return tube off of the pipe.

        Note


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

        • Do not scratch or allow foreign matter to adhere to the parts when disconnecting the fuel tube connector as the fuel tube connector contains the O-ring that seals the pipe.

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

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

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

        • If the fuel tube connector and pipe are stuck, push and pull the connector to disconnect it.

    4. Disconnect the fuel tank main tube.


      1. A01IPPCE01
        Text in Illustration
        *1 Retainer
        *2 Fuel Tube Connector
        *3 O-Ring
        *4 Pipe

        Pinch the tabs of the retainer of the fuel tube connector to detach the lock claws and push the retainer down as shown in the illustration.

      2. Pull the fuel tank main tube off of the pipe.

        Note


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

        • Do not scratch or allow foreign matter to adhere to the parts when disconnecting the fuel tube connector as the fuel tube connector contains the O-ring that seals the pipe.

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

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

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

        • If the fuel tube connector and pipe are stuck, push and pull the connector to disconnect it.

    5. Using a transmission jack, support the fuel tank.

    6. A01IMXH

      Remove the 4 bolts and 2 fuel tank bands.

    7. Lower the transmission jack to remove the fuel tank.

      Note


      • 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.

  18. REMOVE NO. 1 FUEL TANK CUSHION


    1. A01IN9E

      Remove the 4 No. 1 fuel tank cushions.

  19. REMOVE NO. 2 FUEL TANK CUSHION


    1. A01IUGF

      Remove the 2 No. 2 fuel tank cushions.

  20. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A01IOFR

      Loosen the hose clamp bolt, and then remove the filler pipe hose.

  21. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01INSM

      Detach the fuel tank main tube from the 4 clamps and remove it.

  22. REMOVE FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A01INMY

      Detach the fuel tank return tube from the 3 clamps and remove it.