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. REMOVE REAR FLOOR SIDE MEMBER COVER RH

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5. REMOVE REAR SUSPENSION BRACE SUB-ASSEMBLY

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6. REMOVE NO. 1 FUEL TANK PROTECTOR

   
   

   1. 

      Remove the 4 clips as shown in the illustration, and remove the No. 1 fuel tank protector.

7. DISCONNECT FUEL TANK BREATHER TUBE

   
   
   1. 

      Text in Illustration

      *1	Fuel Tank Breather Tube
      *2	Charcoal Canister Outlet Hose
      *3	Breather Tube Clamp

      Loosen the clamp, then disconnect the fuel tank breather tube.

8. DISCONNECT CHARCOAL CANISTER OUTLET HOSE

   
   

   1. Disconnect the charcoal canister outlet hose. and fuel tank breather tube from the No. 1 fuel tube clamp.

   2. Disconnect the charcoal canister outlet hose and fuel tank breather tube from the breather tube clamp.

9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

   
   

   1. 

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

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

    
    

    1. 

       Loosen the clip, then disconnect the No. 1 fuel evaporation tube sub-assembly.

       Note

       
       

       • Remove any dirt or foreign matter on the No. 1 fuel evaporation tube sub-assembly before performing this work.

       • Protect the disconnected part by covering it with a plastic bag after disconnecting the No. 1 fuel evaporation tube sub-assembly.

11. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    
    

    1. Pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank main tube sub-assembly.

       

       Text in Illustration

       *1	Retainer
       *2	Fuel Tube Connector
       *3	Fuel Tank Main Tube
       *4	Fuel Pipe
       *5	O-ring
       	Pull

       Note

       
       

       • Check that there are no scratches or foreign matter around the connected 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 O-rings that seal the fuel pipe.

       • Only disconnect the fuel tube connector by hand.

       • Do not forcibly bend, twist or turn the fuel tank main 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.

12. REMOVE FUEL TANK ASSEMBLY

    
    

    1. 

       Support the fuel tank using an engine lifter.

    2. 

       Remove the 4 set bolts of the 2 fuel tank bands.

    3. Lower the engine lifter to remove the fuel tank.

       Note

       
       

       • Slowly operate the engine lifter to lower the fuel tank.

       • Do not drop the fuel tank.

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

13. REMOVE NO. 1 FUEL TANK CUSHION

    
    
    1. 

       Text in Illustration

       *1	No. 1 Fuel Tank Cushion
       *2	No. 2 Fuel Tank Cushion

       Remove the 4 No. 1 fuel tank cushions.

14. REMOVE NO. 2 FUEL TANK CUSHION

    
    

    1. Remove the 2 No. 2 fuel tank cushions.

15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

    
    

    1. 

       Disengage the 2 clamps, and then remove the fuel tank main tube sub-assembly.

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

    
    

    1. 

       Disengage the 2 clamps, and then remove the No. 1 fuel evaporation tube sub-assembly.

17. REMOVE CHARCOAL CANISTER OUTLET HOSE

    
    
    1. 

       Text in Illustration

       *1	Charcoal Canister Outlet Hose
       *2	Fuel Tank Breather Tube
       *3	No. 1 Fuel Tube Clamp

       Disconnect the No. 1 fuel tube clamp and remove the charcoal canister outlet hose.

    2. Remove the No. 1 fuel tube clamp from the fuel tank breather tube.

18. REMOVE FUEL TANK TO FILLER PIPE HOSE

    
    

    1. 

       Loosen the hose clamp, and then remove the fuel tank to filler pipe hose.