FUEL TANK REMOVAL

PROCEDURE

  1. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY

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  2. DRAIN FUEL

  3. REMOVE REAR FLOOR SIDE MEMBER COVER LH

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  4. REMOVE REAR FLOOR SIDE MEMBER COVER RH

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  5. REMOVE REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY

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  6. REMOVE REAR NO. 1 FLOOR UNDER COVER

    1. A152321

      Remove the 4 clips and nut.

    2. Loosen the grommet, then remove the rear No. 1 floor under cover.

  7. REMOVE CENTER EXHAUST PIPE ASSEMBLY

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  8. REMOVE NO. 1 FUEL TANK PROTECTOR

    1. A152323

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

  9. DISCONNECT FUEL TANK BREATHER TUBE

    1. A152324C01

      *1

      Fuel Tank Breather Tube

      *2

      Fuel Tank To Filler Pipe Hose

      Loosen the clamp, then disconnect the fuel tank breather tube from the fuel tank filler pipe sub-assembly.

  10. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

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

  11. DISCONNECT FUEL RETURN TUBE SUB-ASSEMBLY

    1. A296057C02

      *a

      Retainer

      *b

      Fuel Tube Connector

      *c

      Fuel Pipe

      *d

      O-ring

      *e

      Nylon Tube
      V100135

      Pinch
      V100136

      Pull

      Pinch the tabs of the retainer to disengage the lock claws and pull it down as shown in the illustration.

    2. Pull out the fuel return tube sub-assembly.

      Note:

      • Check that there are no scratches or foreign matter on the connecting parts 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 nylon 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.

  12. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A296058C02

      *a

      Retainer

      *b

      Fuel Tube Connector

      *c

      Fuel Pipe

      *d

      O-ring
      V100135

      Pinch
      V100136

      Pull

      Pinch the tabs of the retainer to disengage the lock claws and pull it down as shown in the illustration.

    2. Pull out the fuel tank main tube sub-assembly.

      Note:

      • Check that there are no scratches or foreign matter on the connecting parts 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 nylon 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.

  13. REMOVE FUEL TANK ASSEMBLY

    1. A296062

      Remove the 2 bolts and parking brake cable assembly.

    2. A153017

      Support the fuel tank assembly using an engine lifter.

      Tip:

      Using height adjustable attachments and plate lift attachments, place the fuel tank assembly horizontally.

    3. A152325

      Remove the 4 bolts.

    4. Lower the engine lifter to remove the fuel tank assembly.

      Note:

      • Do not drop the fuel tank assembly.

      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

  14. REMOVE NO. 1 FUEL TANK CUSHION

    1. A255969C01

      *1

      No. 1 Fuel Tank Cushion

      Remove the No. 1 fuel tank cushion.

  15. REMOVE NO. 2 FUEL TANK CUSHION (w/ No. 2 Fuel Tank Cushion)

    1. A255970C01

      *1

      No. 2 Fuel Tank Cushion

      Remove the No. 2 fuel tank cushion.

  16. REMOVE FUEL RETURN TUBE SUB-ASSEMBLY

    1. A176176C01

      *1

      Fuel Return Tube Sub-assembly

      Remove the fuel return tube sub-assembly from the fuel tank assembly.

  17. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A176177C01

      *1

      Fuel Tank Main Tube Sub-assembly

      Remove the fuel tank main tube sub-assembly from the fuel tank assembly.