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 REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY

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  6. REMOVE CENTER EXHAUST PIPE ASSEMBLY

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  7. REMOVE NO. 1 FUEL TANK PROTECTOR

    1. A152323

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

  8. DISCONNECT FUEL TANK BREATHER TUBE

    1. A161733C01

      *1

      No. 1 Charcoal Canister Outlet Hose

      *2

      Fuel Tank Breather Tube

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

  9. DISCONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE

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

  10. 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.

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

    1. A294333C02

      *a

      Fuel Pipe

      *b

      Rubber Hose

      *c

      Retainer

      *d

      O-ring
      V100135

      Turn
      V100136

      Pull

      Turn the projections of the retainer to disengage the lock claws, and then pull off the No. 1 fuel evaporation tube sub-assembly.

      Note:

      • Check that there are no scratches or foreign matter around the connecting part of the fuel tube connector and fuel pipe before performing this work.

      • 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.

      • Only disconnect the fuel tube connector by hand.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

  12. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A289977C02

      *a

      Retainer

      *b

      Fuel Tube Connector Cover

      *c

      Fuel Tube Connector

      *d

      Fuel Pipe

      *e

      Nylon Tube

      *f

      O-ring

      Release the lock of the fuel tube connector cover as shown in the illustration, then pull off the fuel tank main tube sub-assembly.

      Note:

      • Check that there are no scratches or foreign matter on the connecting parts of the fuel tube connector and fuel pipe before performing this work.

      • 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.

      • Only disconnect the fuel tube connector by hand.

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

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

  13. REMOVE FUEL TANK ASSEMBLY

    1. A296062

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

    2. A153017

      Support the fuel tank assembly using an engine lifter.

      Tip:

      Using a height adjustable attachment and plate lift attachment, place the fuel tank assembly horizontally.

    3. A152325

      Remove the 4 bolts.

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

      Note:

      • Do not drop the fuel tank assembly.

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

  14. REMOVE NO. 1 FUEL TANK CUSHION

    1. A289964C01

      *1

      No. 1 Fuel Tank Cushion

      *2

      No. 2 Fuel Tank Cushion

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

  15. REMOVE NO. 2 FUEL TANK CUSHION

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

  16. REMOVE NO. 4 FUEL TANK CUSHION

    1. A288161

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

  17. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A176167C01

      *1

      Fuel Tank Main Tube Sub-assembly

      Remove the fuel tank main tube sub-assembly from the fuel tank assembly.

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

    1. A176168C01

      *1

      No. 1 Fuel Evaporation Tube Sub-assembly

      Remove the No. 1 fuel evaporation tube sub-assembly from the fuel tank assembly.

  19. REMOVE NO. 1 CHARCOAL CANISTER OUTLET HOSE

    1. A176169

      Disconnect the clamp, and remove the No. 1 charcoal canister outlet hose from the fuel tank assembly.