FUEL TANK REMOVAL

PROCEDURE

  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE 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 TAIL EXHAUST PIPE ASSEMBLY

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  6. REMOVE NO. 1 FUEL TANK PROTECTOR

    1. A286556

      Remove the 4 bolts and No. 1 fuel tank protector from the fuel tank assembly.

  7. DISCONNECT FUEL TANK BREATHER TUBE

    1. A161733C01

      *1

      No. 1 Charcoal Canister Outlet Hose

      *2

      Fuel Tank Breather Tube

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

  8. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE

    1. Disconnect the No. 1 charcoal canister outlet hose from the fuel tank filler pipe sub-assembly.

  9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

    1. A161734

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

  10. DISCONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

    Note:

    Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

    1. A347609C02

      *a

      Fuel Tube Connector

      *b

      Fuel Pipe

      *c

      Retainer

      *d

      O-ring
      V100135

      Pinch
      V100136

      Pull off

      Disconnect the No. 1 fuel evaporation tube sub-assembly from the fuel pipe.

      1. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note:

        • Be sure to disconnect the fuel tube connector by hand.

        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe (fuel pipe).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  11. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    Note:

    Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

    1. A350903C02

      *a

      Fuel Pipe

      *b

      Retainer

      *c

      O-ring

      *d

      Fuel Tube Connector

      *e

      Claw
      V100135

      Push
      V100136

      Pull out
      V100137

      Pull off

      Disconnect the fuel tank main tube sub-assembly from the fuel pipe.

      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note:

        • Be sure to disconnect the fuel tube connector by hand.

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

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  12. REMOVE FUEL TANK ASSEMBLY

    1. A296062

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

    2. A292688

      Support the fuel tank assembly using an engine lifter.

      Tip:

      Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

    3. A286557

      Remove the 4 bolts and 2 fuel tank bands.

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

      Note:

      • Be careful not to drop the fuel tank assembly.

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

  13. REMOVE NO. 1 FUEL TANK CUSHION

    1. A350905

      Remove the No. 1 fuel tank cushion from the fuel tank assembly.

  14. REMOVE NO. 2 FUEL TANK CUSHION

    1. A350906

      Remove the 3 No. 2 fuel tank cushions from the fuel tank assembly.

  15. REMOVE NO. 4 FUEL TANK CUSHION

    1. A288161

      Remove the No. 4 fuel tank cushion from the fuel tank assembly.

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

    1. A355118C01

      *1

      No. 1 Fuel Evaporation Tube Sub-assembly

      Disengage the 2 claws to remove the No. 1 fuel evaporation tube sub-assembly from the fuel tank assembly.

  17. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A355119C01

      *1

      Fuel Tank Main Tube Sub-assembly

      Disengage the 2 claws to remove the fuel tank main tube sub-assembly from the fuel tank assembly.

  18. REMOVE NO. 1 CHARCOAL CANISTER OUTLET HOSE

    1. A289965C01

      *1

      No. 1 Charcoal Canister Outlet Hose

      Disengage the clamp to disconnect the No. 1 charcoal canister outlet hose from the evaporation vent tube clamp.

    2. Disengage the 2 claws to remove the No. 1 charcoal canister outlet hose from the fuel tank assembly.