FUEL TANK REMOVAL

PROCEDURE

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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2. DRAIN FUEL

3. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

   Note:

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

   1. 

      *a	Retainer
      *b	Fuel Pipe
      *c	Nylon Tube
      *d	Fuel Tube Connector
      *e	O-ring
      *f	Claw
      	Push
      	Pull out
      	Pull off

      Disconnect the fuel tank main tube sub-assembly.

      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 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.

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

      3. Check if there is any 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.

5. DISCONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY

   Note:

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

   1. 

      *a	Fuel Tube Connector
      *b	Fuel Pipe
      *c	Retainer
      *d	O-ring
      	Pinch
      	Pull

      Disconnect the No. 1 fuel emission tube sub-assembly.

      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 allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the fuel pipe.

      3. Check if there is any 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.

6. REMOVE FUEL TANK FILLER PIPE SUB-ASSEMBLY

   1. Remove the fuel tank cap assembly.

   2. 

      Remove the bolt.

   3. Loosen the clamp, then remove the fuel tank filler pipe sub-assembly from the fuel tank to filler pipe hose.

7. SEPARATE PARKING BRAKE CABLE ASSEMBLY

   1. 

      Remove the 2 bolts and separate the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly.

8. REMOVE CENTER LOWER FUEL TANK PROTECTOR

   1. 

      Using a T20 "TORX" socket wrench, remove the 3 "TORX" screws and center lower fuel tank protector from the fuel tank sub-assembly.

9. REMOVE FUEL TANK SUB-ASSEMBLY

   1. 

      Support the fuel tank sub-assembly using an engine lifter.

      Tip:

      Using height adjustment attachments and plate lift attachments, place the fuel tank sub-assembly horizontally.

   2. 

      Remove the 4 bolts.

   3. Lower the engine lifter to remove the fuel tank sub-assembly.

      Note:

      • Do not drop the fuel tank sub-assembly.

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

10. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. 

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

11. REMOVE NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY

    1. 

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

12. REMOVE FUEL TANK TO FILLER PIPE HOSE

    1. 

       Loosen the clamp, then remove the fuel tank to filler pipe hose from the fuel tank sub-assembly.