FUEL TANK REMOVAL

PROCEDURE

  1. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY (for Sedan)

  2. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY (except Sedan)

  3. DRAIN FUEL

  4. REMOVE REAR FLOOR SIDE MEMBER COVER LH (w/ Cover)

  5. REMOVE REAR FLOOR SIDE MEMBER COVER RH (w/ Cover)

  6. REMOVE REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY

  7. REMOVE REAR NO. 1 FLOOR UNDER COVER

    1. A355142C01
      V100135

      Grommet

      V100136

      Nut

      Remove the 4 clips and nut.

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

  8. REMOVE CENTER EXHAUST PIPE ASSEMBLY

  9. REMOVE NO. 1 FUEL TANK PROTECTOR

    1. A322267C01
      V100135

      Bolt

      V100136

      Nut

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

  10. 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.

  11. 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.

  12. DISCONNECT FUEL RETURN TUBE SUB-ASSEMBLY

    Note:

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

    1. Disconnect the fuel return tube sub-assembly from the fuel pipe.

      1. A353598C01

        *a

        Retainer

        *b

        Fuel Tube Connector

        *c

        Fuel Pipe

        *d

        O-ring

        *e

        Nylon Tube

        V100135

        Push

        V100136

        Pull off

        Push 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 O-rings that seal the pipe (fuel pipe).

        • Do not bend, twist, pinch or kink the nylon tube.

      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.

  13. 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. A355144C01

      *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.

  14. REMOVE FUEL TANK ASSEMBLY

    1. A296062

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

    2. A353600

      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. A152325

      Remove the 4 bolts.

    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.

  15. REMOVE NO. 1 FUEL TANK CUSHION

    1. A255969C01

      *1

      No. 1 Fuel Tank Cushion

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

  16. 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 from the fuel tank assembly.

  17. REMOVE FUEL RETURN TUBE SUB-ASSEMBLY

    1. A176176C01

      *1

      Fuel Return Tube Sub-assembly

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

  18. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A176177C01

      *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.