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. A292687

      Remove the 3 bolts and No. 1 fuel tank protector from the fuel tank assembly.

  7. DISCONNECT FUEL TANK VENT HOSE

    1. A354385

      Loosen the clamp, then disconnect the fuel tank vent hose from the fuel tank filler pipe sub-assembly.

  8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

    1. A354379

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

  9. 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. Push the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        A354383C01

        *A

        w/o Combustion Type Power Heater

        *B

        w/ Combustion Type Power Heater

        *a

        Fuel Tube Connector

        *b

        Fuel Pipe

        *c

        Retainer

        *d

        O-ring

        *e

        Nylon Tube

        -

        -
        V100135

        Push

        		 V100136

        Pull off
        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.

  10. DISCONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (w/ Combustion Type Power Heater)

    1. A354381

      Slide the clip and disconnect the No. 2 fuel main tube sub-assembly from the fuel pipe.

  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. 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.

        A354387C01

        *A

        w/o Combustion Type Power Heater

        *B

        w/ Combustion Type Power Heater

        *a

        Retainer

        *b

        Fuel Pipe

        *c

        Fuel Tube Connector

        *d

        O-ring

        *e

        Claw

        -

        -
        V100135

        Push

        		 V100136

        Pull out
        V100137

        Pull off

        -

        -
        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. A354389C01

      *A

      w/o Combustion Type Power Heater

      *B

      w/ Combustion Type Power Heater

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

  14. REMOVE NO. 2 FUEL TANK CUSHION

    1. A354390C01

      *A

      w/o Combustion Type Power Heater

      *B

      w/ Combustion Type Power Heater

      Remove the No. 2 fuel tank cushion from the fuel tank assembly.

  15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A355137

      w/o Combustion Type Power Heater:

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

    2. A355136

      w/ Combustion Type Power Heater:

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

  16. REMOVE FUEL RETURN TUBE SUB-ASSEMBLY

    1. A354393

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