FUEL TANK REMOVAL

PROCEDURE

  1. REMOVE FRONT FLOOR COVER

    1. A271430

      Remove the bolt and nut.

    2. Detach the 4 clips and remove the front floor cover.

  2. REMOVE NO. 1 FUEL TANK PROTECTOR

    1. A271431

      Detach the 3 clips and remove the nut and No. 1 fuel tank protector.

  3. REMOVE NO. 1 FLOOR UNDER COVER

    1. A271432

      Detach the clip and remove the 2 nuts and No. 1 floor under cover.

  4. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY

    1. A271433

      Remove the 2 bolts and disconnect the No. 2 parking brake cable assembly.

  5. DISCONNECT FUEL TANK RETURN TUBE

    1. A271434

      Slide the clamp and disconnect the fuel tank return tube from the fuel pipe.

  6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A271435

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

      Click here

  7. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

    1. A271436

      Disconnect the fuel tank to filler pipe hose from the fuel tank assembly.

  8. DISCONNECT FUEL TANK BREATHER HOSE

    1. A271437

      Disconnect the fuel tank breather hose from the fuel tank assembly.

      Click here

  9. REMOVE FUEL TANK ASSEMBLY

    1. Set an engine lifter underneath the fuel tank assembly.

    2. Disconnect the wire harness from the 2 fuel tube grommets.

    3. A124665

      Remove the 2 bolts and No. 1 fuel tank band sub-assembly.

    4. Remove the 2 bolts and No. 1 fuel tank band sub-assembly LH.

    5. Remove the 2 bolts and No. 2 fuel tank band sub-assembly.

    6. Slightly lower the engine lifter.

      Note:

      Be careful not to cut the wire harness.

    7. Disconnect the fuel sender gauge connector and remove the fuel tank assembly.

      Note:

      • Before this procedure, check the connector for dirt, mud or other contamination.

      • Do not use any tools in this procedure.

  10. REMOVE FUEL EMISSION HOSE

    1. A271438

      Detach the clamp and remove the fuel emission hose.

      Click here

  11. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A209413

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

      Note:

      • Before removing a tube joint clip, check for foreign matter around the tube joint clip. Clean if necessary.

      • Do not use any tools in this procedure.

      • Do not forcefully bend or twist the fuel tank main tube sub-assembly.

      • Put the fuel tank main tube sub-assembly in a plastic bag to prevent damage and contamination.

      • If the fuel tank vent tube assembly and fuel tank main tube sub-assembly are stuck together, pinch the fuel tank main tube sub-assembly and turn it carefully to disconnect it.

      • Be careful not the damage any tube joint clip. If a tube joint clip is damaged, replace it.

  12. DISCONNECT FUEL TANK RETURN TUBE

    1. A209414

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

      Note:

      • Before removing a tube joint clip, check for foreign matter around the tube joint clip. Clean if necessary.

      • Do not use any tools in this procedure.

      • Do not forcefully bend or twist the fuel tank return tube.

      • Put the fuel tank return tube in a plastic bag to prevent damage and contamination.

      • If the fuel tank vent tube assembly and fuel tank return tube are stuck together, pinch the fuel tank return tube and turn it carefully to disconnect it.

      • Be careful not the damage any tube joint clip. If a tube joint clip is damaged, replace it.

  13. REMOVE FUEL TANK VENT TUBE SET PLATE

    1. A125359

      Remove the 8 bolts and fuel tank vent tube set plate.

  14. REMOVE FUEL TANK VENT TUBE ASSEMBLY

    A271439

    1. Slide the 2 clamps, disconnect the 2 fuel hoses and remove the fuel tank vent tube assembly.

      Note:

      Do not damage the fuel tank vent tube assembly.

    2. Remove the gasket from the fuel tank vent tube assembly.

  15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A125367

      Remove the fuel tank main tube sub-assembly from the No. 5 fuel tube clamp and 3 fuel tube grommets.

  16. REMOVE FUEL TANK RETURN TUBE

    1. Remove the fuel return tube from the No. 5 fuel tube clamp and 3 fuel tube grommets.

  17. REMOVE NO. 5 FUEL TUBE CLAMP

    1. Remove the No. 5 fuel tube clamp from the fuel tank assembly.

  18. REMOVE FUEL TUBE GROMMET

    1. Remove the 3 fuel tube grommets from the fuel tank assembly.

  19. REMOVE FUEL SENDER GAUGE ASSEMBLY

    Click here